638 Series - HVS System [PDF]

07-02-12-02-EN-V0608.doc. 638 Series Digital. Servo Drive. Product. Manual ... Bus Interface DeviceNet. UL 07-09-04-02.

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Idea Transcript


638 Series

Digital Servo Drive

Product Manual 07-02-12-02-EN-V0608.doc

Additional Supporting Documentation UL: CD EASYRIDER® Windows - Software

UL: 07-02-0902

HIPERFACE® Feedback System

UL: 07-05-0203

Product Manual - Bus Interface SUCOnet K

UL: 07-05-0302

Product Manual Bus Interface CAN

UL: 07-05-0402

Product Manual - Bus Interface Profi Bus DP

UL: 07-05-0502

Product Manual - Bus Interface Interbus S

UL: 07-05-0702

Product Manual - I/O Interface

UL: 07-05-0802

Product Manual - Bus Interface DeviceNet

UL 07-09-04-02 Product Manual - Suppression Aids EH

UL: 10-06-03 Product Manual – Serial Tranfer Protocol EASY-Serial

2

07-02-12-02-EN-V0608.doc / Type: 638

Additional Supporting Documentation UL: 10-06-05 Product Manual - BIAS® Commands

UL: 12-01 Product Manual - Plugs

UL: 12-02 Product Manual - Cables

UL: 12-03 Product Manual - Ballast Resistors

©Parker Hannifin GmbH Co. KG All rights reserved. No portion of this description may be produced or processed in any form without the consent of the company. Changes are subject to change without notice. Parker Hannifin has registered in part trademark protection and legal protection of designs. The handing over of the descriptions may not be construed as the transfer of any rights.

Made in Germany, 2008

07-02-12-02-EN-V0608.doc / Type: 638

3

Table of Contents Page

The Most Important Thing First ............................................................................. 8 Safety Precautions .................................................................................................. 9 1 General Information................................................................................... 11 1.1 ● ● ● ● 1.2 ● ● ● 1.3 ● ●

System Description ...........................................................................................................................11 Special Features of the 638 Servo Drive ..........................................................................................11 Overview of Standard Digital Communication ..................................................................................11 Determining Criteria for the Utilization of the 638 Drive....................................................................12 Operation Configuration ....................................................................................................................12 Model Code .......................................................................................................................................13 Combination Possibilities for the Various Communication / I/O - Modules.......................................14 Module Slots Layout..........................................................................................................................15 Module Design ..................................................................................................................................15 Dimensions........................................................................................................................................16 638A Series.......................................................................................................................................16 638B Series.......................................................................................................................................17

2

Connection Assignments and Functions ............................................... 18

2.1 2.2 ● ● 2.3 ● ● ● ● 2.4 ● ● ● 2.5 2.6 ● ● 2.7 ● 2.8 ● ● ● ● 2.9 ● ● ● ● ● ● 2.10 ● 2.11 ● ● − 2.12 ● ● −

Insulation Concept ............................................................................................................................18 Overview of Compact Unit Connections ...........................................................................................19 638A01.. to 638A06.. ........................................................................................................................19 638B03.. to 638B15.. ........................................................................................................................20 Assignments Power Connections .....................................................................................................21 Power, Ballast, DC Bus - Connection X60........................................................................................21 24V - Control Supply Voltage X01 ....................................................................................................21 Motor - Connection X61 ....................................................................................................................21 Brake / Thermo - Connection X62 ....................................................................................................22 Feedback Sensor X30.......................................................................................................................23 Feedback - Module X300 ..................................................................................................................23 Feedback Connection X30 (SUB D 09 Socket) ................................................................................24 Feedback - Module X300 with Memory 638A ...................................................................................25 Service-Interface COM1 (RS232) .....................................................................................................26 Safe Torque Off.................................................................................................................................27 Connection Safe Torque Off X11 ......................................................................................................27 Connection WITHOUT the utilization of the Safe Torque Off, (STO), function.................................27 Signal Connection .............................................................................................................................28 Control Signal Plug X10 (SUB D25 Socket) .....................................................................................28 Multi-Function X40 ............................................................................................................................29 Incremental - Output .........................................................................................................................30 Incremental - Input ............................................................................................................................30 Stepper Motor Input ..........................................................................................................................31 SSI-Encoder Interface.......................................................................................................................32 Fieldbus Interface COM2 ..................................................................................................................33 Pinning for RS232 .............................................................................................................................33 Pinning for RS422/485 ......................................................................................................................33 Pinning for CAN or DeviceNet...........................................................................................................34 Pinning for Profibus DP.....................................................................................................................34 Pinning for SUCOnet K .....................................................................................................................34 Pinning for EA5 I/O-Interface (Digital In and Outputs)......................................................................35 Fieldbus Interface COM2 in Combination with COM3 (OPTION SLOT A/B) .................................36 Pinning for Interbus S (RP IBS) ........................................................................................................36 Fieldbus Interface RP 2CA, 2C8 .......................................................................................................37 Pinning CAN1-BUS and CAN2-BUS.................................................................................................37 Pinning RP 2C8 X120 (with I/O’s) .....................................................................................................37 DIP Switch Position for Option Module RP 2CA and RP 2C8 ..........................................................38 Fieldbus Interface RP CCA, CC8......................................................................................................39 Pinning CAN1-BUS, CAN2-BUS and RS485....................................................................................39 Pinning RP CC8 X120 (with I/O’s) ....................................................................................................39 DIP Switch Position for Option Module RP CCA and RP CC8 .........................................................40

4

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Table of Contents Page

Connection Assignments and Functions 2.13 ● ● − 2.14

Fieldbus Interface RP PCA, PC8 ......................................................................................................41 Pinning Profibus DP and CAN2-BUS and RS485 ............................................................................41 Pinning RP PC8 / X120 (with I/O’s)...................................................................................................41 DIP Switch Position for Option Module RP PCA, PC8 .....................................................................42 Overview of the Terminal Cross Section...........................................................................................43

3

Operating Mode ......................................................................................... 44

3.1 3.2 3.3 3.4

Operating Mode General...................................................................................................................44 Operating Modes and Pin Functions.................................................................................................45 Configurable Pin Functions (Operating Mode Dependent)...............................................................46 Functions Diagrams with Protection Mode “Switch Off” ...................................................................47

4

Mechanical Installation ............................................................................. 49

4.1 4.2 4.3

Mounting............................................................................................................................................49 Control Cabinet Mounting .................................................................................................................49 Cooling and Ventilation .....................................................................................................................49

5

Electrical Installation................................................................................. 50

5.1 ● ● ● ● ● ● 5.2 ● ● ● ● – ● 5.3 ● ● ● ● ● ● 5.4 ● ● ● 5.5 ● ●

Installation General ...........................................................................................................................50 Safety ................................................................................................................................................50 Danger of Electric Shock...................................................................................................................50 Dangerous Areas ..............................................................................................................................50 Grounding - Safety Grounding ..........................................................................................................50 Ground Connections .........................................................................................................................50 Short-Circuit Capacity and Discharge Currents................................................................................50 Power Mains Connection ..................................................................................................................51 Types of power mains .......................................................................................................................51 Mains supply voltage range 638A .....................................................................................................51 Mains supply voltage range 638B/C .................................................................................................51 Protective Ground Connection (PE)..................................................................................................51 Cable cross section...........................................................................................................................51 Dimensioning of power mains cable and the over-current protection...............................................51 DC Link Parallel Connection .............................................................................................................54 General..............................................................................................................................................54 Variation 1; Servo Drives without DC LINK protection......................................................................54 Variation 2; Servo Drives with DC LINK protection...........................................................................55 Function Softstart ..............................................................................................................................56 Installation Instructions and Warnings ..............................................................................................56 Layout of the Ballast Capacity...........................................................................................................57 Fuses , Contactors ............................................................................................................................58 638A ..................................................................................................................................................58 638B ..................................................................................................................................................58 638C..................................................................................................................................................58 Brake Resistor...................................................................................................................................59 Selection of the Brake Resistor.........................................................................................................59 Configuration of the Brake Resistor ..................................................................................................60

6

Wiring Instructions .................................................................................... 62

6.1 ● ● ● ● ● 6.1 ● ●

General Wiring Instructions...............................................................................................................62 General Information ..........................................................................................................................62 Control Cabling..................................................................................................................................62 Power Cabling ...................................................................................................................................62 Analog Setpoint .................................................................................................................................62 Safety Rules ......................................................................................................................................62 Electromagnetic Compatibility (EMC) ...............................................................................................63 Hints for Mounting .............................................................................................................................63 Example for Mounting .......................................................................................................................64

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Table of Contents Page

7

Hardware Configuration............................................................................ 65

7.1 ● ●

Jumpers.............................................................................................................................................65 Power Board Layout Plan 638A ........................................................................................................66 Power Board Layout Plan 638B/C ....................................................................................................66

8

Commissoning........................................................................................... 67

8.1 8.2 8.3 ● ● ● ● 8.4 ● ● 8.5 ● ● 8.6 8.7 8.8

Commissioning Preparation ..............................................................................................................67 Step 1 : Wiring and Communications Test........................................................................................68 Step 2 :Feedback Test and Motor Selection.....................................................................................69 Step 2.2 Motor Selection...................................................................................................................70 Step 2.3 Motor with Resolver Feedback ...........................................................................................71 Step 2.4 Motor with HIPERFACE Feedback.....................................................................................71 Step 2.5 Motor with SIN-COS Feedback Linear Motor.....................................................................71 Step 3 : Power Up and Drive Activation............................................................................................72 Step 3.1 Power Up ............................................................................................................................72 Step 3.2 Drive Activation...................................................................................................................72 Step 4 : Control Loop Optimization ..................................................................................................73 Step 4.1 Control Loop Optimization with Rotary Motors...................................................................73 Step 4.2 Control Loop Optimization with Linear Motors ...................................................................74 Step 5 : Operation Mode Selection ...................................................................................................75 Step 6 : Fieldbus Interface ................................................................................................................76 Step 7 : Data Save ............................................................................................................................77

9

Safe Torque Off (STO) ............................................................................... 79

9.1 ● ● ● ● ● ● 9.2 ● ● 9.3 9.4 ● ● ● ● 9.5 9.6

General Introduction..........................................................................................................................79 Important Technical Terms and Explanations...................................................................................79 Stop Category according to EN 60204-1 (Chapter. 9.2.2)................................................................80 Applications in Accordance with the Regulations .............................................................................81 Trained Personnel.............................................................................................................................81 Benefits with the Employment of the Safe Torque Off Function .......................................................81 Safety Instructions and Limitations ...................................................................................................82 Safe Torque Off Function, (STO) ......................................................................................................83 Block Circuit Diagram........................................................................................................................83 Status Diagram and Function of Terminals STO1# und STO2# ......................................................84 Configuration and Parameter Settings..............................................................................................85 Application Example of STO (Safe Torque Off) ................................................................................90 Application Example 1.......................................................................................................................91 Application Example 2.......................................................................................................................92 Application Example 3......................................................................................................................93 Application Example 4.......................................................................................................................94 STO Function Test ............................................................................................................................95 Signal Inputs Technical Data - Terminal Connection X11 ................................................................97

10

Diagnosis and Trouble-Shooting ............................................................. 98

10.1 10.2 10.3

7-Segment-Display............................................................................................................................98 Reset of a Drive Trouble .................................................................................................................103 Trouble-Shooting.............................................................................................................................104

11

Standards and Certifications.................................................................. 105

11.1

Compliance with Regulations, Limitations and Basic Conditions ...................................................105

6

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Table of Contents Page

12

Technical Data ......................................................................................... 107

12.1 ● ● ● ● ● ● ● ● ● ● ● ● 12.2 ● ● ● ● ●

General Technical Data ..................................................................................................................107 Power Circuit ...................................................................................................................................107 Control Circuit..................................................................................................................................107 Signal Inputs and Outputs - Connection X10..................................................................................107 Thermo-Control X30........................................................................................................................107 Thermo-Control X62........................................................................................................................108 Brake-Control X62...........................................................................................................................108 Signal Inputs and Outputs - Connection X120B resp. 120C...........................................................108 Digital Control..................................................................................................................................109 Digital Communication ....................................................................................................................109 Resolver Evaluation / Transmitter Principles ..................................................................................109 Controller System............................................................................................................................110 Mechanical Data .............................................................................................................................110 Technical Unit Data.........................................................................................................................111 638A ................................................................................................................................................111 Output Power 638A.........................................................................................................................112 Singlephase and Threephase supply..............................................................................................112 638B ................................................................................................................................................113 Output Power 638B.........................................................................................................................114

13

Software.................................................................................................... 115

13.1 13.2 ● ● ● ● 13.3

EASYRIDER® Windows - Software ................................................................................................115 Introduction......................................................................................................................................116 Program layout ................................................................................................................................117 Execute a BIAS program.................................................................................................................117 Execute a PLC program..................................................................................................................118 Execute a Mathematics program ....................................................................................................118 BIAS - Commands...........................................................................................................................119

14

Appendix .................................................................................................. 120

14.1

STO - Safety - Parameter - Report - Proposal................................................................................120

15 16

Memo ........................................................................................................ 121 Modification Record ................................................................................ 122

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The Most Important Thing First The Most Important Thing First

Thank you for your confidence in choosing our products. These operating instructions are intended to provide an overview of the technical data and features of our products.

Please read the operating instructions completely before operating the product. Should you have any questions, please contact your nearest service representative.

Improper application of this product in combination with dangerous high voltage can lead to serious injury or death.

Damage can also occur to motors or other products. Therefore, we request that you strictly observe our safety and installation instructions.

Safety Precautions We assume that as an expert, you are familiar with and will observe all of the relevant safety regulations, especially in accordance with VDE 0100, VDE 0113, VDE 0160, EN 50178, the accident prevention regulations of the employer’s liability insurance company and the DIN regulations. Additionally, it is imperative that all relevant European Union Safety Directives be observed. Depending on the type and location of the installation, additional regulations, e.g. UL, DIN, must also be fully observed. If our products are operated in connection with components from other manufacturers, their operating instructions are also subject to be strictly observed.

8

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Safety Precautions Safety Precautions Digital servo drives, corresponding to EN 61800-5-1/VDE 0160, are electronic power components utilized for the regulation of the flow of energy in highvoltage electrical power installations. They are exclusively designed, configured and approved to supply our servo motors. Handling, installation, operation, and maintenance are only permitted under the conditions of and in keeping with the effective and/or legal regulations, regulation publications and this technical document.

Attention !

The operator must make sure that these regulations are strictly followed. The Concept of Galvanic Separation and Insulation: Galvanic separation and insulation corresponding to EN 61800-5-1/VDE 0160, provides for additional insulation protection. In addition, all digital signal inputs and outputs are provided with a galvanic separation utilizing either a relay or an optical coupler. In this way, an increased level of protection against potential interference and a limitation of potential damage due to incorrect connections are provided. The voltage level must not exceed the designated low safety voltage of 60V DC or 25V AC, respectively, in accordance with EN 61800-5-1/VDE 0160. The operator must make sure that these regulations are strictly followed.

High Voltage! Danger of Electrocution! Life Threatening Danger!

Danger !

Certain parts of the servo drive are supplied with dangerous electrical current. Physical contact with these components can cause death, life threatening injuries and/or serious damage to equipment and property.

Due to safety considerations and product guarantees, the operator is prohibited from opening the servo drive case. Service, maintenance and repair of our products should only be carried out by specified representatives of the company. Expert configuration and professional installation, as described by this document, are the best way to insure problem-free operation of our servo drives!

Caution !

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9

Safety Precautions

Please Observe !

Pay Special Attention to the Following: Permissible Protection Class: Protective Grounding - operation is only permitted when the protective conductor is connected according to regulations. Operation of the servo drive when employing a residual current operated protective device as the sole protection against indirect touching, is not permissible. The servo drive may only be used in conjunction with machines or electrical systems when placed in control cabinets which comply with EEC- Directive98/37EEC (Machine Directive) and EEC Directive 89/336/EEC (EMC – Directive). Work on or with the servo drive may only be carried out with insulated tools. Installation work may only be done in a de-energized state. When working on the drive, one should not only block the active input, but also separate the drive completely from the main power connection. CAUTION - Risk of Electrical Shock: Wait 3 minutes after switching the component off to allow the capacitors to discharge. Screws sealed with varnish fulfill an important protection function and may not be tampered with or removed. It is prohibited to penetrate the inside of the unit with objects of any kind. Protect the unit from falling parts, pieces of wire, metal parts, etc., during installation or other work in the control cabinet. Metal parts can lead to a short-circuit in the servo drive. Before putting the unit back into operation, remove any additional covers so that the unit does not overheat. When conducting measurements on the servo drive it is imperative to pay attention to the electrical isolation.

We are not liable for damage which may occur when the product instructions and/or the applicable regulations are not explicitly observed!

Stop !

10

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1

General Information

1

General Information

1.1 ●

System Description Special Features of the 638 Servo Drive • The digital 638 servo drive provides for the electrical connection, rotational speed and position control of the AC servo motor. • All of the functions and system controls are digitally regulated, employing a sampling rate of 105µs. • The 638 servo drive supports the safety function ”Safe Torque Off“, STO, providing for a definitive system shut-down, for protection against an unanticipated start-up, in accordance with the requirements as stated in EN 13489-1, Category 4, Performance Level e and EN1037. • The feedback generated from the braking energy is dissipated through the employment of internal ballast resistance and when required through the employment of additional external ballast resistance. • The AC supply voltage can be directly connected or it can be connected through a transformer, as required. (Important: only operated on networks which are grounded at the centre point (TN networks) • The servo drive additionally requires a 24 V DC control supply voltage connection. • The built-in internal EMC filter corresponds to the requirements regarding susceptibility to interference for industrial systems as described in EN50081-1. • By employing various option modules, through 2 additional plug-in receptacles, it is possible to increase the potential connections to the field bus system and/or the input/output terminals. • Various motor feedback loop systems can be supported by employing the flexible feedback module X300. • Through the employment of additional 638 drives it is optionally possible to couple the DC link. • Minimal Housing Dimension is provided through the intelligent compact design of the unit.



Overview of Standard Digital Communication

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11

1 ●

General Information Determining Criteria for the Utilization of the 638 Drive Decisions relating to the appropriate selection of the motor type, feedback system and drive type, as well as the system layout and option modules required, are dependant upon the specific application and the anticipated operating mode of the system. There are 6 operating modes to choose from:

• 0 Seed / Current control switchable via Input X10.24 • 1 Speed control • 2 Current control • 3 Speed / Position control switchable via Input X10.24 • 4 Position control without BIAS – execution • 5 Position control with BIAS - execution



Operation Configuration There are opportunities ranging from simple current and speed control to programmable position control processes (PLC), supported by the 1500 BIAS command blocks. "BIAS" User shell for intelligent drive controls: See Chapters: “■ Operation Modes“ and “■ Software“

12

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1

General Information

1.2

Model Code Special

Marking Type:

a 638

b X

c XX

d X

e F

Marking a b

f X

g STO

h XXX

h1 XXX

i XXX

j XXX

Description 638

=

6th. Generation Digital Servo Drive

A

=

01 02 04 06

= = = =

Size A Rated Current: 1,0 amps 2,0 amps 4,0 amps 6,0 amps

3

=

e

F A

= =

Size: Size B C = Size C Rated Current: 03 = 2,5 amps 05 = 5,0 amps being prepared 08 = 7,5 amps 10 = 10,0 amps 15 = 15,0 amps Intermediate Voltage: 638A 638B 325 VDC / 230 VAC 3 = 325 VDC / 230 VAC 6 = 565 VDC / 400 VAC 7 = 678 VDC / 480 VAC With Integrated Filter = Standard less leakage current (AC-side Y-capacitators deactivated; JP600 open)

f

0

=

Without EMC - Clip

c

d

g STO = h 000 232 422 485 CAN 2CA 2C8 CCA PC8 DEV SUC PDP IBS PC8 PCA EA5

= = = = = = = = = = = = = = = =

h1 000 = EAE =

B

=

Safety Performance: Safe Torque Off = Standard Additional option-module RP -XXX on the drive for communication via COM2 No Option RS 232 interface ≅ slot A (A, B) RS 422 interface ≅ slot A (B) RS 485 interface ≅ slot A (B) CAN – Bus ≅ slot A (B) 2 x CAN (without I/O’s) ≅ slot B (A) / [C*] 2 x CAN + 4 outputs and 4 inputs ≅ slot B (A) / [C*] 2 x CAN + RS 485 ≅ slot B (A) 2 x CAN2 + 4 outputs and 4 inputs + RS 485 ≅ slot B (A) CAN - Bus / DeviceNet ≅ slot B (A) SUCOnet K ≅ slot B (A) Profibus DP ≅ slot B (A) Interbus S ≅ slot B (A) Profibus DP + CAN2 + 4 outputs and 4 inputs + RS 485 ≅ slot B (A) Profibus DP + CAN2 + RS 485 ≅ slot B (A) I/O - Interface (5 inputs, 2 outputs) ≅ slot B (A) Additional Options Module on the drive via X200 No Option I/O - Interface (14 inputs, 10 outputs)

RM1 = HM1 = SM1 =

X300 – Functions Module Standard X30 Resolver – Module 2nd Version HIPERFACE® – Module 2nd Version Sine / Cosine - Module 2nd Version with Memorychip as of firmware V 8.35 Resolver + Memory- Module 2nd Version HIPERFACE® + Memory- Module 2nd Version Sine/Cosine + Memory- Module 2nd Version

X7x BSx

Enter only when used Broad-band contact X10.7 - X10.8 Moisture/Condensation Protection

i RD2 = HF2 = SC2 =

j = =

= Standard

≅ slot C = Standard

≅ slot D ≅ slot D ≅ slot D ≅ slot D ≅ slot D ≅ slot D

*Only CAN2 can be employed when utilizing the option module located at slot [C], (internal BUS / COM3 B).

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13

1 ●

General Information Combination Possibilities for the Various Communication / I/O - Modules Slot Option Module

A 2 3 2

4 2 2 -

4 8 5 -

C A N -

2 C A -

2 C 8 -

C C A -

C C 8 -

D E V -

B S U C -

P D P -

I B S -

E A 5 -

P C 8 -

P C A -

C E *2 *2 A C C E A 8 -

Model Code 638xxxxFxSTO232000xxx 638xxxxFxSTO232EAExxx 638xxxxFxSTO2322CAxxx 638xxxxFxSTO2322C8xxx 638xxxxFxSTO422000xxx 638xxxxFxSTO422EAExxx 638xxxxFxSTO4222CAxxx 638xxxxFxSTO4222C8xxx 638xxxxFxSTO485000xxx 638xxxxFxSTO485EAExxx 638xxxxFxSTO4852CAxxx 638xxxxFxSTO4852C8xxx 638xxxxFxSTOCAN000xxx 638xxxxFxSTOCANEAExxx 638xxxxFxSTO2CA000xxx 638xxxxFxSTO2CAEAExxx 638xxxxFxSTO2C8000xxx 638xxxxFxSTO2C8EAExxx 638xxxxFxSTOCCA000xxx 638xxxxFxSTOCCAEAExxx 638xxxxFxSTOCC8000xxx 638xxxxFxSTOCC8EAE xxx 638xxxxFxSTODEV000xxx 638xxxxFxSTODEVEAExxx 638xxxxFxSTOSUC000xxx 638xxxxFxSTOSUCEAExxx 638xxxxFxSTOPDP000xxx 638xxxxFxSTOPDPEAExxx 638xxxxFxSTOPDP2CAxxx 638xxxxFxSTOPDP2C8xxx 638xxxxFxSTOIBS000xxx 638xxxxFxSTOIBSEAExxx 638xxxxFxSTOIBS2CAxxx 638xxxxFxSTOIBS2C8xxx 638xxxxFxSTOEA5000xxx 638xxxxFxSTOEA5EAExxx 638xxxxFxSTOPC8000xxx 638xxxxFxSTOPC8EAExxx 638xxxxFxSTOPCA000xxx 638xxxxFxSTOPCAEAExxx 638xxxxFxSTO000EAExxx 000 = No Option Possible Combination * Only CAN2 can be employed when utilizing the option module located at slot [C], (internal BUS / COM3 B)

Example: 638A043F0STO232EAERD2 638 = 6th. Generation Digital Servo Drive A = Size A 04 = 4 Amps Rated Current 3 = 325 VDC (230 VAC) F = With Integrated Filter 0 = Without EMC - Clip STO = Safe Torque Off 232 = RS 232 Interface ≅ on slot A EAE = I/O Interface 14/10 ≅ on slot C RD2 = Standard X30 Resolver ≅ on slot D (Motor - Feedback system)

14

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1 ●

General Information Module Slots Layout Module Slots: A

232 422 485 CAN

B

2CA 2C8 CCA CC8 DEV SUC

C

PDP IBS EA5 PCA PC8

EAE *2CA *2C8

Motor - Feedback System:

D



RD2: Standard Resolver HF2: Option HIPERFACE® SC2: Option Sine / Cosine with Memorychip as of FW V8.35 RM2: Resolver + Memory HM2: HIPERFACE® + Memory SM2: Sine/Cosine + Memory

Module Design Design A

Design B

Design C

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15

1

General Information

1.3

Dimensions



638A Series

Important: Please note that on the front side of the unit, approximately 70 mm of additional space is required for the signal mating plugs! When installing multiple servo drives, there is minimum space on the side. The unit should only be mounted vertically as shown.

16

07-02-12-02-EN-V0608.doc / Type: 638

1 ●

General Information 638B Series

Important: Please note that on the front side of the unit, approximately 70 mm of additional space is required for the signal mating plugs! When installing multiple servo drives, there is minimum space on the side. The unit should only be mounted vertically as shown.

07-02-12-02-EN-V0608.doc / Type: 638

17

2

Connection Assignments and Functions

2

Connection Assignments and Functions

2.1

Insulation Concept The insulation of the 638 units is achieved in various insulation classes or groups.

18

07-02-12-02-EN-V0608.doc / Type: 638

2 2.2 ●

Connection Assignments and Functions Overview of Compact Unit Connections 638A01.. to 638A06..

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19

2 ●

20

Connection Assignments and Functions 638B03.. to 638B15..

07-02-12-02-EN-V0608.doc / Type: 638

2 2.3 ●

Connection Assignments and Functions Assignments Power Connections Power, Ballast, DC Bus - Connection X60 638A Plug - X60 PIN 1 2 3 4 5 6 7

Designation 0VP RB1/+UCC RB2 L1 L2 L3 / N PE

Function 0 Volt DC Bus External – Ballast Resistor / + DC - Bus External – Ballast Resistor Power Connection 1, 230V AC Power Connection 2, 230V AC Power Connection 3, 230V AC / Ground Protective Ground

638B Plug - X60 PIN 1 2 3 4 5 6 7



Designation 0VP RB1/+UCC RB2 L1 L2 L3 PE

Function 0 Volt DC Bus External – Ballast Resistor / + DC - Bus External – Ballast Resistor Power Connection 1, 400V AC Power Connection 2, 400V AC Power Connection 3, 400V AC / Ground Protective Ground

24V - Control Supply Voltage X01 Plug - X01



PIN

Designation

1 2 3 4

+24V +24V 0V 0V

Function Supply Us (Input) Supply Us (Output with PIN 1 jumpered) Reference Potential 0V Reference Potential 0V

Setup and Wiring example

Motor - Connection X61 638A

Plug - X61 PIN

Designation

Function

1

M1 / U

Motor Supply

2

M2 / V

Motor Supply

3

M3 / W

Motor Supply

4

PE

Protective Ground

638B

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21

2 ●

Connection Assignments and Functions Brake / Thermo - Connection X62 638A

Stecker - X62 PIN

Bezeichnun g

1

+24V

Input; Supply Voltage Mechanical Brake

2

0V

Input; Refer. Potential Supply Voltage Mechanical Brake

3

BR+

Control Mechanical Brake

4

BR-

Control Mechanical Brake

5

-

Not assigned

6

TH+

Thermo PTC1) /NTC

7

TH-

Thermo PTC1) /NTC

1)

22

Funktion

638B

Setup and Wiring example

With parameter setting PTC can you temperature sensor Typ KTY (note poling) or thermo switch used. EASYRIDER Menu „Configuration Motor / X30 Switch off at:“ use resistor value in Ohm. For thermo switch is the value 1000 Ohm in the EASYRIDER Menu „Configuration Motor / X30 Switch off at:“

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2 2.4

Connection Assignments and Functions Feedback Sensor X30 The feedback system creates a digital value from the feedback position sensor. From this value the following is derived: Commutation according to the pole division Actual rotational speed value Position value for the position controller



Feedback - Module X300 The X30 connection is directly connected to the Feedback - Module X300.The mode of operation of the feedback system is specified by this plug-in module. (see: ● Layout Module Slots) The 638 – Drive system therefore offers a built-in flexibility and provides for the possibility of future modification. 638B 638A

Model Type X300 Description X300_RD2 Resolver X300_HF2 HIPERFACE® X300_SC2 Sine/Cosine X300_RM1 Resolver + Memory X300_HM1 HIPERFACE®+ Memory X300_SM1 Sine/Cosine + Memory Additional types available upon request.

Standard Option Option Option as of Firmware V 8.35 Option as of Firmware V 8.35 Option as of Firmware V 8.35

Plug and Play The 638 Servo Drive is able to identify the type of X300 Module employed. The EASYRIDER® Windows – Software loads the correct function code. You follow the instructions in the EASYRIDER® Windows – Software. For feedback module RD2 the function code is already pre-set (factory default).

Note

When employing the Feedback Module X300_HF2 (HIPERFACE®), please pay attention to documentation 07-02-09-02-E-Vxx.

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23

2 ●

Connection Assignments and Functions Feedback Connection X30 (SUB D 09 Socket) Pinning for the Motor - Feedback - Socket X30 when employed with: Resolver Module X300_RD2 or X300-RM1(Standard Module) Module: X300_RD2 / X300_RM1 PIN X30

1 2 3 4 5 6 7 8 9 1)

24

Function

PTC1) / NTC optional cos + sin + carrier + PTC1) / NTC optional cos sin carrier -

Setup and Wiring example

With parameter setting PTC can you temperature sensor Typ KTY (note poling) or thermo switch used. EASYRIDER Menu „Configuration Motor / X30 Switch off at:“ use resistor value in Ohm. For thermo switch is the value 1000 Ohm in the EASYRIDER Menu „Configuration Motor / X30 Switch off at:“

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2

Connection Assignments and Functions HIPERFACE® - Module X300_HF2 or X300_HM1 Module: X300_HF2 / X300_HM1 PIN X30

Function

1 2 3 4 5 6 7 8 9

GND 10 VDC cos + sin + data ref cos ref sin data +

Sine / Cosine - Module X300_SC2 or X300_SM1 Module: X300_SC2 / X300_SM1 PIN X30

1 2 3 4 5 6 7 8 9



Function

GND 5,5 V cos + sin + zero pulse ref cos ref sin zero pulse +

Feedback - Module X300 with Memory

638A

As of firmware version V8.35 the 638 Drive supports the X300-xM-Modules. This module has an additional memory chip (Flash). This flash stores the complete drive data. (firmware, function code, parameters, application program) When a drive is defect the X300-memory module can be replaced with the complete drive data in the new drive. You need no additional configuration work or software tools. Requirement: The drive type must be equal (same current)! Attention during the 1.st switch on of the control voltage after the X300 module replacement! After the replacement of the X300 module, make sure that the 1st switch on of the 24V control voltage has no interruption during 60 seconds. (It is necessary that the copy program for Firmware and X300 Feedback function code are not interrupted.) Applications in Accordance with the Regulations When the 638A Drive supports the safety function “Safe Torque Off”, in the sense of providing a definitive stopping of the equipment, with protection against unanticipated start-up, in accordance with regulations EN954-1, Category 3 and EN, after the X300 module change one must follow the instructions completely as stated in the validation report.

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25

2

Connection Assignments and Functions

2.5

Service-Interface COM1 (RS232) Functions: Supports all diagnostic and parameter configuration activities PC connection utilizing our communications cable KnPC/D Communication utilizing our operational program software (EASYRIDER® Windows - Software)

Com 1 RS232

Function Drive Side PIN

RS232 on PC PIN

4-Pin Modular Plug

RXD TXD

Receive Serial Data Send Serial Data Do Not Connect Ground

GND

1 2 3 4

Order code KnPC637+/631-03.0 KnPC637+/631-05.0

Length 3m 5m

3 2

TXD RXD

5

GND

Description PC-Side Sub D 09-Plug Drive-Side 4-Pin RJ 10-Plug

Note: The service interface port is not galvanically separated and should therefore not be used as the operations interface port (fixed wiring)! The network connection with the PC must be located near the Drive in order to receive the reference potentials of the units together.

26

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2 2.6 ●

Connection Assignments and Functions Safe Torque Off Connection Safe Torque Off X11 Plug - X11 PIN 1 2 3 4 5 6

Description STO1 # STO1 # 0V / PE STO2 # -

Function Channel 1 (ACTIVE_STO1) Channel 1 (ACTIVE_STO1) Parallel to PIN 1 Reference Potential 0V Channel 2 (ACTIVE_STO2) Ready potential-free contact assembly Ready potential-free contact assembly

Further description of this function can be found in Chapter “Safe Torque Off“ (STO)



Connection WITHOUT the utilization of the Safe Torque Off, (STO), function Input ACTIVE (24V) 0VSPS

PIN 1 2 3 4 5 6

Description STO1 # STO1 # 0V / PE STO2 # -

The control supply voltage must be definitively separated, in accordance to regulation EN 1578

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27

2

Connection Assignments and Functions

2.7

Signal Connection



Control Signal Plug X10 (SUB D25 Socket) Inputs / Outputs Control Signal Plug X10 PIN X10 1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18

19 20 21 22 23 24 25

Function

Type

Description

Shielding Connection Screen Configurable (Operating Mode) OPTO Input Stabilized Auxiliary Supply Voltage Output -12VDC; max. 80 mA Auxiliary Supply Voltage Configurable (Operating Mode) OPTO Input Reference Point to X10.18 Input Analog 0...+/-10V / Ri = 10 kOhm Configurable Output Analog Through JP100 (soldered jumper) Optional assignable as a free and loopable potential for the READY Contacts ON: Drive trouble free Relays Output OFF: Drive problem or Constant: Ready power supply interruption Reference Point for Digital Input Reference Point for Digital Inputs Ground for Analog Signal Ground Configurable (Operating Mode) OPTO Input Configurable (Operating Mode) OPTO Output Configurable (Operating Mode) OPTO Output Configurable (Operating Mode) OPTO Configurable (Operating Mode) OPTO Stabilized Auxiliary Supply Voltage +12V DC; max 80 mA Configurable Rotational Speed Setpoint; Scaleable differential with respect to X10.5 Specifications for the Power Limits can be activated and are scaleable (0..+10V for 0.. Imax) Configurable (Operating Mode) OPTO Nominal: 24VDC Configurable (Safety Functions) OPTO Configurable (Operating Mode) OPTO Configurable (Operating Mode) OPTO

Input Input Output Auxiliary Supply Voltage Output Analog Input Analog 0...+/-10V / Ri = 10 kOhm Input Analog 0..+10V Ri = 10 kOhm Output Supply for Outputs Input Input Input

Data for the digital in and outputs: See Chapter. “■ General Technical Data“

28

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2

Connection Assignments and Functions

2.8

Multi-Function X40 Description of the X40: Via a programmable I/O processor, the X40 connection can be configured differently. EASYRIDER® Windows - Software Standard functions: - Incremental output - Incremental input - Stepper motor - pulse inputs - SSI interface The unobstructed configurability provides ideal conditions for synchronous applications.

General Data Plug Type: Maximum Input or Output Frequency: Maximum Cable Length - connected to galvanically insulated terminals (Encoder, controls) Maximum Cable Length - connected to ground related terminals (other drives, controls) Maximum Number of Signal Inputs - to one as incremental output configured device Output Signals: Differential Logic Level: Nominal Range: Input Signals: Differential Input Level: Nominal Signal Difference: Current Consumption:

X40 SUB D 09 male plug 312 kHz 25 m; For extended distances please contact our engineer 2 m, Pay attention to provide for good common grounding ! 8 Driver Model MAX483 or compatible, RS422 L ≤ 0,5V H ≥ 2,5V 0,0 ... 5,0V 150mA max. Receiver Model MAX481 or compatible, RS422 Diff min = 0,2V 1,0V 1...4 mA (depending on the frequency)

Notice: Master / Slave Operation 1 Master, Maximum 8 Slaves Condition: Devices must be located directly side by side!

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29

2 ●

Connection Assignments and Functions Incremental - Output

EASYRIDER® Windows - X40 Connection: Mode = Incremental Output Incremental encoder simulation for processing in positioning modules Standard: 1024 increments with Pulse Duty Cycle Additional selectable pulse settings: 16384, 8192, 4096, 2048, 512, 256, 128, 64 Inc. I/O X40 PIN X40 1 2 3 4 5 6 7 8 9

Function

Designation

Channel B Channel B - Inverted Shield Connector Channel A Channel A - Inverted Reference *

B /B Shield A /A GND /Z Z + 5 VDC

Channel Z - Inverted Zero Impulse Channel Z, zero impulse Supply Voltage Output Max. 150 mA

Pulse resulution ≥1024 Incr./rpm 2048 Incr./rpm 4096 Incr./rpm 8192 Incr./rpm 16384 Incr./rpm

Max. permissible speed 12000 rpm 7600 rpm 3800 rpm 1900 rpm 950 rpm

Design Rule: The input frequency range of the connected control must equal at least the value of the pulse output frequency on the X40. n = max. speed (rpm) x = increments e.g. 1024 f = output frequency at X40.1,2,4,5

Formula: f = 1,2 * (n * x) = [Hz]

60

Example: n = 4000 1/min

f=



1,2 * (4000 * 1024) = 81920 Hz 60

Incremental - Input EASYRIDER® Windows - Software X40 Connection: Mode = Incremental Input Parameter range of the input signals: 10...1000000 increments Figure:

Note: The operation of incremental encoders via long cables may cause a voltage drop of the encoder power supply. We recommend the use of a separate voltage supply if necessary.

30

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2 ●

Connection Assignments and Functions Stepper Motor Input Two different modes are available EASYRIDER® Windows - Software X40 Connection: Mode = Stepper Motor (Pulse+Direction) EASYRIDER® Windows - Software X40 Connection: Mode = Stepper Motor (2*Pulse) INCR. I/O X40 PIN X40 1 2 3 4 5 6 7 8 9

Function Mode: Pulse+Direction Mode: 2*Pulse Output: Drive Active - Inverted Output: Drive Active Shield Connector Pulse Inverted Pulse - Inverted Pulse Pulse Reference Potential (generally to connect)

/READY READY Shield GND

Direction Inverted Pulse + Inverted Direction Pulse + Supply Voltage Output Max. 150 mA

+5 VDC

Designation

Figure: Pulse+Direction

Figure: 2*Pulse

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31

2 ●

Connection Assignments and Functions SSI-Encoder Interface EASYRIDER® Windows – Software • X40 Connection: Modus = SSI_13 Bit Singleturn Input • X40 Connection: Modus = SSI_14 Bit Singleturn Input • X40 Connection: Modus = SSI_25 Bit Multiturn Input / (13 Bit Single- / 12 Bit Multiturn) • X40 Connection: Modus = SSI_26 Bit Multiturn Input / (14 Bit Single- / 12 Bit Multiturn) • X40 Connection: Modus = SSI_18 Bit Multiturn Input / (16 Bit Single- / 2 Bit Multiturn) Incr. I/O X40 PIN X40 1 2 3 4 5 6 7 8 9

Function

Designation

Serial Data from SSI Encoder, GRAY Code up to 26 Bit - Inverted Serial Data from SSI Encoder, GRAY Code up to 26 Bit Shield Connector Clock Output - Inverted Standard Frequenzy: 179 kHz Clock Output Standard Frequenzy: 179 kHz Reference Potential

/DATA

Shield /TAKT

Do Not Connect Do Not Connect Supply Voltage Output Max. 150 mA If other data required: a) Use of X300 Module b) External Supply

+5 VDC

DATA

TAKT GND

TAKT and /TAKT twisted pairs DATA and /DATA twisted pairs Cable Shielded - shielding grounded at both ends, Max. Cable Length: 200m Note: For further information about SSI (Synchronous Serial Interface), please refer to the documentation of the appropriate suppliers. (e.g.: Comp. Sick or Hengstler)

32

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2 2.9

Connection Assignments and Functions Fieldbus Interface COM2 Additional functions can be realized through the optional employment of the Options Modules



Pinning for RS232 Module: RP 232 PIN 1 2 3 4 5 6 7 8 9



Function RXD TXD GND / 485-GND -

Pinning for RS422/485 Module: RP 422 oder RP 485 PIN 1 2 3 4 5 6 7 8 9

Function Data In GND Data In - Inverted Data Out - Inverted Data Out -

Options module RP 422, without galvanic separation Options module RP 485, with galvanic separation Parallel wiring for up to 16 units. (Full - Duplex, 4-Wire)

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33

2 ●

Connection Assignments and Functions Pinning for CAN or DeviceNet Module: RP CAN (CAN BUS1) or RP DEV PIN 1 2 3 4 5 6 7 8 9

Function CAN_L Bus Line (dominant low) Ground Optional Ground

Designation CAN_L

CAN_H Bus Line (dominant high) -

CAN_H

CAN-GND CAN-GND

-

with galvanic separation



Pinning for Profibus DP Module: RP DP PIN 1 2 3 4 5 6 7 8 9

Function

Designation

Line B Request to Send Ground Potential +5V

B RTS PDP-GND +5V A -

Line A with galvanic separation



Pinning for SUCOnet K Module: RP SUC PIN 1 2 3 4 5 6 7 8 9

Function

Designation

Data Line + Signal Ground Data Line -

TA/RA SGND TB/RB -

with galvanic separation

34

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2 ●

Connection Assignments and Functions Pinning for EA5 I/O-Interface (Digital In and Outputs) Module: RP EA5 PIN 1 2 3 4 5 6 7 8 9

Function

Designation

BIAS Input 101 BIAS Input 102 BIAS Input 107 BIAS Input 108 0VSPS

Standard Standard Standard Standard Ground reference 0VSPS Standard Standard Standard Ext. +24V feed-in

BIAS Input 106 BIAS Output 109 BIAS Output 110 +24VSPS

Status Input Input Input Input

B Input Output

A UB

with galvanic separation Notice ! The inputs with the internal numbers 107 and 108 must be connected to pin numbers 3 and 4. The outputs with the internal numbers 109 and 110 must be connected to pin numbers 7 and 8.

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35

2

Connection Assignments and Functions

2.10

Fieldbus Interface COM2 in Combination with COM3 (OPTION SLOT A/B)



Pinning for Interbus S (RP IBS) Remote OUT - Outgoing Interface (SUB D09 Socket) Module: RP IBS PIN

Function Designation Data Line OUT Forward DO2 1 (error voltage A) Data Line IN Backward DI2 2 (error voltage A) 3 Reference Potential IBS-GND 4 5 VCCI +5V Data Line OUT Forward /DO2 6 (error voltage B) Data Line IN Backward /DI2 7 (error voltage B) 8 9 Reporting Input * RBST * for additional Interbus S - Interfaces Remote IN - Incoming Interface (SUB D09 Plug) Module: RP IBS PIN

Function Data Line IN Forward 1 (error voltage A) Data Line OUT Backward 2 (error voltage A) 3 Reference Potential 4 5 Data Line IN Forward 6 (error voltage B) Data Line OUT Backward 7 (error voltage B) 8 9 with galvanic isolation

36

Designation DO1 DI1 IBS-GND /DO1 /DI1 -

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2 2.11 ●

Connection Assignments and Functions Fieldbus Interface RP 2CA, 2C8 Pinning CAN1-BUS and CAN2-BUS Module: RP 2CA, 2C8 PIN 1 2 3 4 5 6

Function

Designation

CAN_L Bus Line (dominant low) Ground Optional Ground

-

CAN_H Bus Line (dominant high) -

7 8 9

CAN2

CAN1

CAN_L CAN-GND CAN-GND CAN_H -

with galvanic isolation



Pinning RP 2C8 X120 (with I/O’s) X120 1 2 3 4 5 6 7 8 9 10

Function 0

1

Reset Drive Fault BIAS Limit Switch + BIAS Limit Switch Reference BIAS Switch BIAS Cam 1 BIAS Cam 2 BIAS Cam 3 BIAS Cam 4 Ext. +24 V Supply Ground Reference 0 V BIAS

BIAS PIN

Status

Input 121

Input

Input 122 Input 123

Input Input

Input 124

Input

Output 125 Output 126 Output 127 Output 128 -

I/O’s

Output Output Output Output Ub B

The signal status of the I/O’s is shown with a 2mm LED LED on I/O = high / LED off I/O = low. (min./max. cable cross-section: 0,08mm² / 1,5mm²)

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37

2 −

Connection Assignments and Functions DIP Switch Position for Option Module RP 2CA and RP 2C8 DIP – Switch Position CAN

DIP – Switch Position BUS – Termination (Example 638A)

38

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2 2.12 ●

Connection Assignments and Functions Fieldbus Interface RP CCA, CC8 Pinning CAN1-BUS, CAN2-BUS and RS485 Module: RP CCA, CC8 PIN 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

Function

Designation

CAN_L Bus Line (dominant low) Ground Optional Ground

CAN_L

CAN_H Bus Line (dominant high) CAN2 CAN_L Bus Line (dominant low) Ground Ground CAN_H Bus Line (dominant high) -

CAN_H

CAN-GND CAN-GND

CAN1

RS485 Data-IN inv. 485-/CAN-GND DATA-IN GND (optional) 485-/CAN-GND -

CAN2-BUS / RS485

Data-OUT Data-OUT inv.

with galvanic isolation



Pinning RP CC8 X120 (with I/O’s) X120 1 2 3 4 5 6 7 8 9 10

Function 0

1

Reset Drive Fault BIAS Limit Switch + BIAS Limit Switch Reference BIAS Switch BIAS Cam 1 BIAS Cam 2 BIAS Cam 3 BIAS Cam 4 Ext. +24 V Supply Ground Reference 0 V BIAS

BIAS PIN

Status

Input 121

Input

Input 122 Input 123

Input Input

Input 124

Input

Output 125 Output 126 Output 127 Output 128 -

I/O’s

Output Output Output Output Ub B

The signal status of the I/O’s is shown with a 2mm LED LED on I/O = high / LED off I/O = low. (min./max. cable cross-section: 0,08mm² / 1,5mm²)

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39

2 −

Connection Assignments and Functions DIP Switch Position for Option Module RP CCA and RP CC8 DIP – Switch Position CAN

40

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2 2.13 ●

Connection Assignments and Functions Fieldbus Interface RP PCA, PC8 Pinning Profibus DP and CAN2-BUS and RS485 Module: RP PCA, PC8 PIN 1 2 3 4 5 6 7 8 9

Designation

Line B Request to Send Ground Potential +5V

B RTS PDP-GND +5V A RS485 Data-IN inv. -

Line A CAN2 CAN_L Bus Line (dominant low) Ground Ground

1 2 3 4 5 6

CAN_H Bus Line (dominant high) -

7 8 9



Function

485-/CAN-GND DATA-IN GND (optional) 485-/CAN-GND

Profibus DP

CAN2-BUS / RS485

Data-OUT Data-OUT inv.

Pinning RP PC8 / X120 (with I/O’s) X120 1 2 3 4 5 6 7 8 9 10

Function 0

1

Reset Drive Fault BIAS Limit Switch + BIAS Limit Switch Reference BIAS Switch BIAS Cam 1 BIAS Cam 2 BIAS Cam 3 BIAS Cam 4 Ext. +24 V Supply Ground Reference 0 V BIAS

BIAS PIN

Status

Input 121

Input

Input 122 Input 123

Input Input

Input 124

Input

Output 125 Output 126 Output 127 Output 128 -

I/O’s

Output Output Output Output Ub B

The signal status of the I/O’s is shown with a 2mm LED LED on I/O = high / LED off I/O = low. (min./max. cable cross-section: 0,08mm² / 1,5mm²)

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41

2 −

Connection Assignments and Functions DIP Switch Position for Option Module RP PCA, PC8 DIP – Switch Position CAN2 / RS485 and Profibus DP

Further information for the Profibus DP: See Documentation 07-05-04-02-E-Vxxxx.

42

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2 2.14

Connection Assignments and Functions Overview of the Terminal Cross Section Cross Section

638A [mm2]

Solid Core / Multiple conductor line Flexible with ferrule without plastic sleeve Flexible with ferrule with plastic sleeve Flexible with TWINferrule with plastic sleeve Approbation Data UL/C-UL-US CSA Stud Torque [Nm] Solid Core and X01 Multiple conductor line Control Voltage Flexible with ferrule X11 without plastic sleeve STO, Active Flexible with ferrule with X62 plastic sleeve Brake, Flexible with TWINThermo ferrule with plastic sleeve Approbation Data UL/C-UL-US CSA Stud Torque [Nm] Solid Core / X61 Multiple conductor line Motor Flexible with ferrule without plastic sleeve Flexible with ferrule with plastic sleeve Approbation Data UL/C-UL-US CSA Stud Torque [Nm] Solid Core and X120 Multiple conductor line Option 2C8, PC8, CC8 Approbation Data UL/C-UL-US CSA X60 Line, Brakeresistor , DC-Link

638B [mm2] 0,2-10 0,2-6

638C [mm2] 0,75-16 0,75-16

0,25-2,5

0,25-6

0,5-16

0,25-2,5

0,25-4

0,5-16

0,5-1

0,25-1,5

0,5-6

0,2-2,5

[AWG] 30-12 28-12 0,5-0,6

Spring tension

1,7-1,8

0,14-1,5

0,14-1,5

0,14-1,5

0,25-1,5

0,25-1,5

0,25-1,5

0,25-0,5

0,25-0,5

0,25-0,5

0,5-1

0,25-1

0,25-1

[AWG] 30-14 30-14 0,2-0,22 0,2-2,5 0,2-2,5

[AWG] 30-14 30-14 0,2-0,22 0,2-10 0,2-6 0,25-6

[AWG] 30-14 30-14 0,2-0,22 0,2-10 0,2-6 0,25-6

0,25-4

0,25-4

[AWG] 30-12 28-12 0,5-0,6

[AWG] 28-8 28-8 0,7-0,8

[AWG] 28-8 28-8 0,7-0,8

0,08-1,5

0,08-1,5

0,08-1,5

[AWG] 28-14 28-14

[AWG] 28-14 28-14

[AWG] 28-14 28-14

0,25-2,5 0,25-2,5

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[AWG] 20-6

43

3

Operating Mode

3

Operating Mode

3.1

Operating Mode General The preselection of the device functions are carried out by choosing the operating modes 0...5 according to the following table, see: ■ Operating modes and pin functions, (EASYRIDER® Windows - Software). Each operating mode allows for the assignment of different in and output functions (F0..F6).

Operating Mode

Reference Source

Hints for Selecting the Operating Mode

0 1 2

Analog (X10.5/18)

Switching the operating modes 1 and 2 through input X10.24 Speed control analog Torque controller analog

3

Analog (X10.5/18) / Digital

Simple applications with the requirement of switching between position and speed control position controller (input X10.24). Handling like operating mode 4

4

Digital or Analog in acc. to parameter setttings

5

Digital or Analog in acc. Simple to complex systems using BIAS instructions to programming or via (up to 1500 command blocks) digital communication PLC Functions (e.g. fieldbus)

44

General position controlled systems - Up to 10 positions can be stored under identifier-numbers and activated as shown.

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3 3.2

Operating Mode Operating Modes and Pin Functions 0 Available Torque / SpeedControl Contact Numbers

1 Speed Control

Operating Modes 2 3 Torque Position / Control Speed Control

4 Position Control

5 Position Control + BIAS Functions

Input X10.14

F0, F1

F0, F1

F0, F1

F0, F1, F2, F3

F0, F1, F2, F3,F6

F0, F1, F2,F6

Input X10.15

F0, F1

F0, F1

F0, F1

F0, F1, F2, F3

F0, F1, F2, F3,F6

F0, F1, F2,F6

Input X10.4

---

---

---

---

F2,F6

F0, F2, F3,F6

Input X10.25

---

---

---

---

F2,F6

F0, F2, F3,F6

Input X10.11

F1

F1

F1

F1

F1,F2,F6

F0, F1, F2, F3,F6

---

---

F1, F2,F6

F1, F2, F3,F6

Input X10.24

F0 L = torqueH = speed control

F0 L = torqueH = speed control

Input X10.2

---

---

---

---

F0

F2, F3

Output X10.12

F0, F2, F5

F0, F2, F5

F0, F2, F5

F0, F1,F3, F5

F0, F1,F3, F5

F0, F1, F2, F3, F4, F5

Output X10.13

F0, F2, F5

F0, F2, F5

F0, F2, F5

F0, F1,F3, F5

F0, F1,F3, F5

F0, F1, F2, F3, F4, F5

Output X10.20

F0, F2, F5

F0, F2, F5

F0, F2, F5

F0, F1,F3, F5

F0, F1,F3, F5

F0, F1, F2, F3, F4, F5

Output X62.3 X62.4

F0, F2, F5

F0, F2, F5

F0, F2, F5

F0, F1,F3, F5

F0, F1,F3, F5

F0, F1, F2, F3, F4, F5

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45

3

Operating Mode

3.3

Configurable Pin Functions (Operating Mode Dependent) Input Functions (Operating Mode Dependent)

Input Nr.

Function F0

Input X10.14 Input X10.15

Function F1







3) 1) move manually limit switch - set selection data 2a





extended latch

Input X10.25

latch input 2

Input X10.11

3) start (slope 0>1) for BIAS regulator trouble reset move commands 3) operating mode selection reference sensor (0) – 1or 2 (3) – 1or 4



Input X10.2

start (slope 0-->1) with position set selection in position control (4)



Output X10.12

position reached

reference output

Output X10.13

temperature monitoring

reference output

Output X10.20

warning

reference output

Output X62.3 X62.4

active ok (motor brake)

1)

2) 3)

46

Function Function Function F4 F5 F62)

⌧ latch input 1



Function F3

3) 1) move manually + limit switch + set selection data 20

Input X10.4

Input X10.24

Function F2

reference output

1) set selection data 2b 1) set selection data 2c 1) set selection data 2d 1) set selection data 2max

strobe (slope 0-->1) for BIAS-set selection

⌧ ⌧ ⌧ ⌧

⌧ ⌧ ⌧

⌧ ⌧ ⌧

CAN Node no. 20 CAN Node no. 2a



CAN Node no. 2b



CAN Node no. 2c



CAN Node no. 2d







CAN Node no. 2max









tracking window exceded tracking window exceded tracking window exceded tracking window exceded

synchronformat trigger

no drive trouble

-

start offset trigger

no regulator trouble



no drive trouble

-

no drive trouble

-



-

BIAS function is freely programmable in operating mode 5. - No function in operating modes 0 to 4.

Fast input for optimal timing. With every row (from the top to the bottom) in which the function F2 is assigned to an input, the binary value (2n) increases by 1. (See example) Operating mode 4: Only numbers 0 - 9 are allowed to be set! Only possible with module RP-CAN. If the Option RP 2C8 / PC8 (See: Fieldbus - interface - COM2-COM3) is inserted, the contact functions as described for the X10-plug are not valid. The inputs are freely programmable utilizing the BIAS program.

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3 3.4

Operating Mode Functions Diagrams with Protection Mode “Switch Off” In accordance with EASYRIDER® Windows – Software “Commissioning / Motor / Motor/30”

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47

3

48

Operating Mode

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4 4

4.1

Mechanical Installation Mechanical Installation

Mounting In order to guarantee the best possible air circulation for the cooling unit, the servo drive should only be installed in a vertical position. The vertical installation above other systems or heat producing units can cause overheating.

4.2

Control Cabinet Mounting Installation should be carried out only in a control cabinet in which the inside is free from dust, corrosive fumes, gases and liquids. Make absolutely sure that the condensing of evaporating liquids including atmospheric moisture is avoided. Should the digital servo drive be installed in a place where condensation is likely, a suitable anti-condensation heater must be installed. The heater must be SWITCHED OFF during normal operation. Automatic switch off is recommended The servo drives should not be installed in areas which have been classified as dangerous, unless they have been installed in an approved enclosure and in accordance with applicable regulations. In such an application double check all aspects of the installation. Please pay attention during installation of the unit to provide for adequate space and ventilation! (See: “■ Dimensions“) General Rule: It is better to place heat-producing devices low in an enclosure to support internal convection and to spread out the heat. If placing such devices up high is unavoidable, enlarging the upper dimensions at the expense of height or the installation of fans should be considered.

4.3

Cooling and Ventilation The digital servo drives are inherently designed to protect against damage which may be caused due to overheating. A temperature sensor is mounted on the heat sink. When the temperature reaches a level above >95°C, the unit will be automatically shut-down. This setting can not be altered. The cooling of the power module will be assisted as much as possible with an internal fan. Depending upon the temperature the fan unit will operate at one of two levels, in order to limit unnecessary wear and potential pollution. Make sure a cabinet of proper size is selected for adequate air circulation. If the device is placed and operated in a non-ventilated environment, the case volume of the specified control cabinet must be calculated in accordance with the following table! Unit 638A01..- 638A06.. 638B03..- 638B05 638B08..- 638B15 638C

Volume / Cabinet 0,12 m³ 0,15 m³ 0,25 m³ 0,35 m³

For more specific information, please refer to the information provided by the manufacturer of the cabinet.

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49

5

Electrical Installation

5

Electrical Installation

5.1

Installation General



Safety The voltages carried by power supply cables, motor cables, connectors, and certain parts of the drive can cause serious electric shock and even death



Danger of Electric Shock

Caution !

Risk of electrical shock, wait 3 minutes after switching off, for discharging of the capacitors. Disconnect the drive unit from the mains before working on it. A period of three minutes must pass after switching off so that the internal capacitors can discharge completely. Until the discharge time is over, there can be dangerous voltage stored in the module ! Persons, who monitor or carry out electrical installation and maintenance must be adequately qualified and schooled in these activities.



Dangerous Areas The use of variable speed drives of all kinds can invalidate the certification for dangerous areas (apparatus group and/or temperature class) of explosion-protected motors. Inspection and certification for the complete installation of servo motors and electronic components must be obtained.



Grounding - Safety Grounding The grounding impedance must meet the requirements of local industrial safety regulations and should be inspected and checked at appropriate and regular intervals



Ground Connections It is recommended to attach a ground bus, made of high conductivity copper, as near as possible to the servo-rack or regulator modules in order to minimize the length of the cable run connections. The recommended dimensions are:

Thickness: d = 5 to 6 mm Length Width (m) (mm) < 0,5 20 0,5 < 1,0 40 1,0 < 1,5 50

d b

grounding bus-bar

l Due to increased discharge currents > DC 10mA resp. > AC 3,5mA the grounding connection of the drive has to be connected 2 times. At power supply connector X60.7 and at the housing grounding screw!



Short-Circuit Capacity and Discharge Currents Due to the working principles of servo drives, there may discharge currents to the ground exceeding DC 10mA resp. AC 3,5mA. Suitable for use in a system capable of delivering not more than 5000 RMS symmetrical amperes 240V (638A) or 480V (638B/C) maximum. (Note according to UL508C)

50

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5 5.2 ●

Electrical Installation Power Mains Connection Types of power mains The 638 servo drives can be directly connected to TT- and TN-Systems (TT- and TN-Systems are three-phase systems with grounded neutral). When using the servo drive in IT mains (three-phase systems without grounded neutral), isolation transformers must be used. The secondary neutral must be grounded and connected to the 638 protective ground conductor. General is valid, that with a phase-earth voltage (rated isolation voltage) > 300V AC the isolation requirements (necessary clearance- and creapage distance, Test voltage, etc.) Concerning the EC Low Voltage Guideline is not filled anymore and so that the CE conformity is not given.



Mains supply voltage range 638A The nominal supply voltage range is 1/3*230V AC +/-10%. Respective intermediate transformers must be used for higher supply voltages. With grounded power mains, autotransformers can also be used to adjust the voltage. Neutral does not have to be connected for this type of transformer. It is possible to use a lower supply voltage range. Note: In this case the internal DC–BUS capacity may be not high enough (specially in 1 phase mains supply) and the user has to adjust the undervoltage monitoring parameter of the drive.



Mains supply voltage range 638B/C The nominal supply voltage range is 3*400 / 480 AC +/-10%. It is possible to use a lower supply voltage range. Note: In this case the internal DC–BUS capacity may be not high enough and the user has to adjust the undervoltage monitoring parameter of the drive.



Protective Ground Connection (PE) The following information concerning the protective ground connection corresponds to EN 61800-5-1 Item 4.2.5.4.1and 4.2.5.4.2.



Cable cross section The cross section for the protective ground conductor at X60 corresponds to the external conductor. The 638 servo drive is a devices with increased leakage current (larger than 3,5 mA AC or 10mA DC). Therefore a second protective ground conductor must be connected at the case-groundbolt. (with the same cross-section as the first protective ground conductor on X60).



Dimensioning of power mains cable and the over-current protection The cross-section from the power main cable and the rated current for the over-current protection should be dimensioned for the average current load to be expected. In the supply line a protection about a protective circuit breaker or fuse shall be provided. Circuit breakers with tripping-characteristic C or fuses with tripping-characteristic gM are to be used. One determines the load to be expected on the average as follows:

[ ]

1-phase supply: I mains A =

S [VA] S [VA] 3-phase supply: I mains[ A] = UNetz[V ] 3 × UNetz[V ]

The apparent power S can be calculated to that as follows:

S [VA] = Meff [Nm ]× k ×

2 × π × naverage[min − 1] 60

The constant k for the different servo drives can be taken from the following table:

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51

5

Electrical Installation Type constant k

638A-1A 1,4

638A-2A 1,22

638A-4A 1,22

638A-6A 1,2

Type constant k

638B-03 1,29

638B-05 1,13

638B-08 1,13

638B-10 1,11

638B-15 1,08

When information about load torque, Inertia and the friction-situation be there, the effective momentum is calculated with following formula: (in case of correct motor dimensioning also the rated torque of the employed motor can be used):

M eff [ Nm ] =

1

T cycle [s ]

×

∑ M [Nm ]2 × t [s ] i

i

i

For the determination of naverage there must be corresponding information about the positioningcycle.

naverage[min − 1] =

1

Tcycle[s ]

× ∑ ni[min − 1] × ti[s ] i

The cross section of the power main cable and the rated current of the used fuse are chosen in accordance with table "Current-carrying capacity of PVC isolated three-phase cable or single conductors" so, that the permissible current-carrying capacity of the chosen cross section larger or alike to the calculated main current. With drive groups this is the sum of the main currents. Icurrent-carrying capacity ≥

Imain

Icurrent-carrying capacity ≥

∑Imain

The rated current of the fuse must be equal to or less than the permissible current-carrying capacity of the chosen cross sectional cable. IR ≤ Icurrent-carrying capacity IR ≤ ∑Icurrent-carrying capacity The following table show the maximum current load of PVC insulated three-phase cables (or conducting wires) according to IEC60204-1 at 40°C environmental temperature and 70°C maximum conductor temperature. Line cross section

[mm2] 0,75 1,0 1,5 2,5 4,0 6,0 10 16

Individual wires in insulating conduit or cable duct B1 [Aeff] 7,6 10,4 13,5 18,3 25 32 44 60

Cable in insulating conduit or cable duct B2 [Aeff]

Cable on walls

Cable in a cable tray

C [Aeff]

E [Aeff]

9,6 12,2 16,5 23 40 40 53

11,7 15,2 21 28 36 50 66

11,5 16,1 22 30 37 52 70

When determinating the cross section for he power mains, make sure that the cross section selected is within the range that can be used with power mains terminal X60. See Assignments Power Connections. –

52

Dimensioning the Line Contactor The rated current of the line conductor is oriented to the over-current for the power mains connection. The line contactor is set up so that nominal operating current specified by the manufacturer of the line contactor for catergory AC-1 is approximately 1.3 times the rated current of the over current protection.

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5 ●

Electrical Installation Fault Current Protection Servo Drive of the 638series can cause a DC current in protective grounding. Where for the protection in case of a direct or indirect contact residual current device (RCD) is used, only a RCD of the type B (AC-DC sensitive) is permissible on the current supply side. If is permissible for application should types with increased trip current (300mA) and/or. short time-delayed to be used. A another preventive measure must be used, e.g. separation from the environment by double or reinforced insulation or separation from the public supply system by a transformer.



Rated Fault Current Line filters have high discharge currents due to intern capacities. In the servo drive of the series 638 an intern line filter is integrated. Additional discharge currents are caused by the capacities of the Motor cable and the motor winding. Through the PWM frequency of the Inverter the leakage current have high frequently rates. The suitability of the RCD is to test for the respective application. Generally we do not recommend the operation with RCD’s. The value of the leakage current depends on the following points: Lenght and characteristic of the motorcable PWM-Frequency Operation with or without shielding How and where is the motor housing grounded Comment: High fault currents can occur: Extreme unbalance factor of the three phase system. When connecting to the power mains (short-term single- or two-phase operation because of contact chatter on the line contactor) Estimation: Single-phase or two-phase operation (as intermediate state when switching on the line contactor):

IA[A] =

UNetz[V ]× 2 × π × fNetz[Hz ]× CA[F ]

Single-phase operation with neutral line:

IA[ A] =

UNetz[V ]× 2 × π × fNetz[Hz ]× CA[F ] 2× 3

3

The discharge capacitance CA the various 638 Servo Drives can be taken from the following table: Servo Drives Filter 638A-01..06 638A-01..06 638A-01..06A LNF RA-230/12 1phase 3phase 1/3phase 1phasig (JP 600 open) Discharge 230nF 277nF 136nF 10nF capacitance -

Servo Drives 638B03..15 3phasig 1610nF

638B03..15 x A 3phasig 200nF

Discharge capacitance Recommendation: For less leakage current operation with 1phase supply it can be recommended the following combination. Use a Servo Drive with the optional Version 638Axx-3-A 1) and a low leakage linefilter Typ LNF RA *230/12. 1) AC-sided Y-Capacitance deactive (JP600 open, see chapter Jumper) When several 638A servo drives operates with 1phase supply and 3 phase are available in the machine, the drives should be divided similar on the 3 phases so that the charging currents obliterate mutually when the system is powered up. Note: It only allowed, to connect the DC-Link Voltage between drives which are connected to the same phase or which have 3 phase supply.

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53

5

Electrical Installation

5.3 ●

DC Link Parallel Connection General With the operation of a group of drives it is possible to couple the DC link circuit of the 638 Drives. Advantages: Positive energy balancing - utilization of braking energy, with energy equalization achieved through the DC link Smaller load on the ballast resistors Increased DC link capacity through smaller residual rippling, specifically with single phase applications Increase of the internal ballast peak performance Increase of the internal ballast continuous power rating Internal unit balancing resistance provides for a uniform rectifier load sharing with a parallel incoming power supply



Variation 1; Servo Drives without DC LINK protection

Block Diagram 1

Advantage: no DC-fuses necessary. Disadvantage: Sum of power limited by line fuse.

54

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5 ●

Electrical Installation Variation 2; Servo Drives with DC LINK protection

Block Diagram 2

Advantage: Sum of power not limited by line fuse. Disadvantage: DC-fuses necessary.

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55

5 ●

Electrical Installation Function Softstart When switch on the supply voltage the DC link capacities become over a resistance loaded. Attain the undervoltage threshold + constant waiting period (2,4s) that becomes charging resistor by a relay bridges. The operating status „undervoltage “changes at the same time in „ready“. When switching the supply voltage off the soft starting function becomes only after falling below undervoltage threshold again actively. It is therefore particularly with intermediate circuit-coupled Drives importantly before restarting the supply voltage to wait to those under voltage threshold is reached. Up to standard undervoltage threshold of 160V the unchargeing time for the 6A-Drives is approx. 30 seconds. Uncharging time to undervoltage threshold (160V) see table: Typ time



638A01..06 max. 30sec.

638B03..05 max. 28sec.

638B08..15 max.42sec.

638C being prepared

Installation Instructions and Warnings The DC-Link connections of the Series 638 are not short circuit - and earth fault proof and not protected against polarity reversal. A short circuit on the DC-Bus wires can be damage the rectifier in the Device. In order to protect the rectifier also in the circuit variant 1, mains fuses of the class gRL must be set in. These are fuses with combined protection for wires and semiconductors. With a common DC link bus, one should employ the 638A Series of Servo Drives exclusively. Drives which are located immediately next to each other, within the same control cabinet, should be carefully arranged with the DC links being made employing a short wire connection. Note: Connect maximum 4 Servo drives together.

Note: Units should be turned on together as shown. (Contactor K1) Switching delays can endanger the function of the rectifier and the “soft-power-up-circuitry“, (wear effect).

Note: The failure of individual AC fuses can go unnoticed as the power continues to be delivered through the DC-bus of the units connected in parallel. Regular checks of the fuses are therefore strongly recommended.

Note: Careful planning and wiring are imperative! A short-circuit on DC bus link connections can cause serious damage to the rectifiers and drives.

Note: With single phase power-supply at 638A Devices it is recommended that only the same phase is used for all coupled drives. The connection of different phases generates a DC-Link voltage of 565V DC! This can damage the devices.

56

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5 ●

Electrical Installation Layout of the Ballast Capacity Energy, which is produced by the electrical brake motor, will be fed into the DC link and then through the DC link coupling to serve other motors within the sequence. Only a portion of the energy which is produced in this manner leads to an increase in the DC link voltage and will then, at a specified voltage threshold, be converted to heat and released through the units’ internal or external ballast. Therefore, an energy exchange occurs between the units, creating a positive energy balancing and overall work load balance of the ballast switches. A significant reduction factor in the load can be anticipated, depending upon the specifics of the installation.

Layout Step by Step (without reduction factors) Addition of all internal unit ballast continuous ratings Addition of all internal unit ballast peak performance ratings For information concerning the required data and design layout of the ballast resistance: See Chapter “● Layout of the Ballast Resistance“ Arrange the external ballast resistance with regard for the braking power occurrence, if possible.

Remarks The load on the internal ballast will be evenly divided between all of the units connected in parallel.

v

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57

5

Electrical Installation

5.4

Fuses , Contactors



638A Servo - Driver Fuse, Contactor FI – Switch Input Supply Current 1 phase Input Supply Current 3 phase Fusible cut-out VDE Automatic circuit breaker VDE Fusible cut-out UL Line contactor Fusible cut-out DC-link resp. AC-supply variant 1



1) [A] 1) [A]

638A02..

Not recommended 2, 8 4,7 1,6

2,7

638A04..

638A06..

9,4

11

5,4

7,8

Type 6..16A gG 6..16A gG 10..16A gG 16A gG Type B6A..16A B6A..16A B10A..16A B16A 2) Type 6A..15A 6A..15A 10..15A 15A 3) Type DILM7 DILM7 DILM7 DILM7 4) Type 10A..16A 10A..16A 10A..16A 10A..16A gRL gRL gRL gRL

638B Servo - Driver Fuse, Contactor FI – Switch Input Supply Current 3 phase Fusible cut-out VDE Automatic circuit breaker VDE Fusible cut-out UL Line contactor Fusible cut-out DC-link resp. AC-supply variant 1



638A01..

638B03..

1) [A]

638B05..

Not recommended. 3,2 5,6

638B08..

8,5

638B10.. 638B15..

8,9

Type 6..16A gG 6..16A gG 10..16A gG 16A gG Type B6A..16A B6A..16A B10A..16A B16A 2) Type 6A..15A 6A..15A 10..15A 15A 3) Type DILM7 DILM7 DILM12 DILM15 4) Type 10A..30A 10A..30A 10A..30A 16..30A gRL gRL gRL gRL

11,4 16A gG B16A 15A DILM15 16A..30A gRL

638C Servo Drive Fuse, Contactor e FI – Switch Input Supply Current 3 phase Fusible cut-out VDE Automatic circuit breaker VDE Fusible cut-out UL Line contactor Fusible cut-out DC-link resp. AC-supply variant 1

638Cxx

1) [A]

638Cxx

Not recommended xx xx

Type 32A gG Type B32A 2) Type 35A 3) Type DILM32 4) Type 32A gRL

40A gG B40A 40A DILM40 40A gRL

1) 2) 3) 4)

At maximum output voltage and rated current. UL listed (JDDZ) Fusible cut-out Class K5 or H, or rather UL listed (JDRX) Class H. Recommended e.g. Klöckner Moeller Class gRL are fuese with combient protect for Cable and Semiconductor. e.g. Fa. SIBA Sicherungs-Bau GmbH Serie 60 034.34.16; Fuseholder 5106304.x (up to 30A) Serie 50124.34.xx, Fuseholder 5105804.3 (up to 40A) If these fuses are used, the mains voltage may only be switched on, when the Softstart - function is active. (Device in Undervoltage operating state).

58

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5 5.5 ●

Electrical Installation Brake Resistor Selection of the Brake Resistor When employing a breaking mechanism with an operating motor driven system, the contained energy flows back into the drive. The capacitors within the motor can absorb a small portion of the excess energy. The rest of the energy must be dissipated through a resistor in heat. The activation of the Brake Resistor occurs, depending upon the voltage threshold. The resistance load is electronically simulated and monitored by our software (EASYRIDER® Windows - Software). Peak power (Pmax) and continuous power output (Pd) must be configured so that the specific requirements of the application are fulfilled. The general rule for resistance measurements is as follows: Pmax / Pd 3 minutes) • The user must ensure protection against accidental touching

62

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6 6.1

Wiring Instructions Electromagnetic Compatibility (EMC) Conformity, in accordance with the EEC Directive 89/336/EEC has been evaluated using a referencesystem, consisting of a compact type drive and a line-filter on mounting-plate, connected to an AC-synchronous motor. The motor cable is mainly responsible for EMC emissions. The motor cable must be installed therefore employing exceptional care. The layout of grounding is very important. Grounding has to be low-impedance for high frequencies. That means, all ground connecting parts have to be connected over a large surface contact area. The measurements provided are valid only with the use of our cables, suppression aids and line filters and by application of the following wiring instructions:



Hints for Mounting A

B

C D E

All components are mounted inside of a steel control cubicle on a mounting plate (min. thickness 3mm). Recommended: Galvanized

3mm

The connection between the drive housing, the filter housing and the mounting plate must be bare metal and not reduced by varnish. All screws must be properly tightened ! Use only our filters and cables for motor and resolver connections. Place all wires and cables as close as possible to grounded metal parts. Separate power and control cables. Minimum distance: 0,3m Cross Points: 90°

F

Avoid cable loops. The run between the line-filter and drive has to be as close and short as possible (drilled).

G

Maintain the shielding as close as possible to the cable-end (max distance 8 cm).

H

I

Connect shielded connections according to general view of connections: See chapter 2.1. Ground shielding on both sides, with the shortest possible cable run. For long cables: Connect additional shielded areas along the way. Connect the shielded area to well grounded points.

K

Connect unused wires in cables to the ground.

L

Install control cables close to grounded metal parts or shielding when leaving the control cubicle Pay close attention to the grounding of controltransformer (DC 24V). Use a transformer with a metal socket and pay attention to provide for good conductive contact on mounting plate. Pay close attention to the overall grounding of the complete system. Interconnect several mounting plates using copper rails or copper band. Pay attention to the ground connection between the control cabinet and the equipment !

0,3 m

90°

8 cm max

M

N

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63

6 ●

Wiring Instructions Example for Mounting X61 Motor Connector Wiring:

64

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7

Hardware Configuration

7

Hardware Configuration

7.1

Jumpers All jumpers are set to a standard preset ! JP100, Bridged Pad 2 and 3 (standard) 1 and 3 JP101, Bridged Pad. 2 and 3 (standard) 1 and 3

READY contact with reference to common output supply voltage on X10.21 READY contact can be freely wired

Analog input X10.19 without internal pull-up. Analog input X10.19 with internal pull-up to +12 V

JP1, JP2, Bridged Pad 2 and 3 (standard) 1 and 3

Adjust identically !! X10.15 = high active X10.15 = low active

JP3, JP4, Bridged Pad 2 and 3 (standard) 1 and 3

Adjust identically ! X10.14 = high active X10.14 = low active

JP2.8, JP2.3, JP2.7, JP2.2 Open Close JP600 Open Close

Default, RP -CAN, -DEV, -2CA, -2C8,-CC8, -CCA, -PDP, -PC8, -PCA, RP -232, -422, -485, -IBS, -EA5, -SUC

Default Minimal current leakage with external filter operation

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65

7 ●

Hardware Configuration Power Board Layout Plan 638A View solder side (solder jumper)



Power Board Layout Plan 638B/C View solder side (solder jumper)

66

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8

Commissoning

8

Commissoning

8.1

Commissioning Preparation

Caution ! Improper installation conditions and/or wiring can cause uncontrolled movement and operation of the equipment. Please carefully observe all safety instructions and regulations for the protection of both the equipment and personnel! It is recommended that one utilize the EASYRIDER® Windows - Software Program for the initial set-up of the equipment. This program communicates through the serial interface of the computer to the attached drive. Information concerning the operation of the EASYRIDER® software is discussed in this chapter. We suggest that the software be first run in the “Simulation“ mode in order for the user to become familiar with and comfortable the system. The EASYRIDER® Windows - Software also provides for additional interactive “Help” functions. Due to security concerns some of the Menus are password protected. The set up and start up of the equipment must be carried out by qualified personnel only. The installation must be performed taking into consideration all of the specific safety regulations and security related functions, concerning the equipment. Double check all safety and security related items, including the limit switch. The conformity of the motor feedback system and the X300 feedback module built-in to the drive must be checked by examining the name plates on the equipment. For the initial equipment start up involving critical applications, we recommend that a test be run without the mechanical connection being made. If problems do arise then they can be solved without risk of damage to any other attached equipment. An experienced installer does have the possibility of tailoring the installation to meet the specific application requirements, provided that he/she assumes all of the responsibility for any alterations or deviations from the prescribed installation instructions.

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67

8

Commissoning

8.2

Step

: Wiring and Communications Test Action, Function

1.1

1 1.2

# 1.3

Anticipated Result

Before Starting the Equipment! Check the wiring; in particular: supply voltage, incoming powerline, motor wiring, motor polarity, feedback system, (Resolver; HIPERFACE® etc.), polarity Sine / Cosine etc. First uncouple the motor shaft, before addressing critical mechanical problems. Connection of the Diagnostic Interface Link for the Drive - COM1 RS232 Connection to the PC and start EASYRIDER Windows Software.

Remark, Cause of Fault Condition 638 Connector Assignment Electrical Installation Wiring Instructions Model Code

-

Limitation of potential danger

EASYRIDER for Windows Software Start side:

EASYRIDER Software Cable Interface USB RS232 Adapter

 ¢ 1.4

Settings for the Connected COM Ports With the PC in Options Menu select „Interface Selection“.

The selected COM Port is shown on the lower right hand corner of the window of the EASYRIDER for Windows Software

The available connections to the PC are shown in the Device Manager under System Control

1.5

Supply Voltage US = 24V DC through X01-Connection to the system.

7 Segment Display:

Pin Assignments for the Power Supply Connection X01

¢ 1.6

7 Segment Display Symbol:

Check the communications connections and functions by utilizing the Diagnosis window or by employing the F9 button on the keyboard.

On to Step

68



EASYRIDER Diagnosis Window:

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It is always the last window where settings have been made which will be opened!



8 8.3

Commissoning Step

. :Feedback Test and Motor Selection Action, Function

2.1.1

1

Anticipated Result

638 X30 Connector Assignment

Prerequisite:

Step The feedback sensor is connected to the 638 Drive through the X30 connection port. Optionally. Temperature sensor and/or Brakre are connected to the X62 connector. (with X62 Thermo notice Step 2.2.3

2.1.2

2.1.3

Remark, Cause of Fault Condition

Make the X30 connection to the drive only when the power supply is disconnected!

638 X62 Connector Assignment

Eliminate the risk of a short circuit!

Check the counter function by looking at the Actual Position Locator – Display 1 under the Drive Diagnosis window of the EASYRIDER Software and the movement of the motor shaft. 34. - with linear motors the movement of the rotor.

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When employing a motor with a brake, make certain that the brake is opened

69

8 ●

Commissoning Step 2.2 Motor Selection

Action, Function

Remark, Cause of Fault Condition

Anticipated Result

638 X61 Connector Assignment

2.2.1

Prerequisite:

1

The motor cable is connected to the 638 Drive through the X61 connection port

2.2.2

In the EASYRIDER configuration menu for „Motor“, select Motor Library and then scroll down to the appropriate motor utilizing the motor type information as listed on the name plate.

2.2.3

Optionally: select temperature sensor

Step

-

When employing motors from other manufacturers it is possible to input and store the specific motor characteristics in the Customer Motor Library.

Select the temperature sensor connection X30 or X62 in EASYRIDER.

638 X30 Connector Assignment

or 638 X62 Connector Assignment

Default : X30

2.2.4

70

In the EASYRIDER configuration menu for „Motor“, send the selected motor information on to the drive and save the selection.

-

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8

Commissoning



Step 2.3 Motor with Resolver Feedback

Action, Function

2.3

☺ 5





Step 2.4 Motor with HIPERFACE Feedback

Action, Function

2.4

Remark, Cause of Fault Condition

With standard motors, equipped with Resolver Feedback, when the unit is properly wired and the proper motor is selected, no additional action is required. For every360° motor shaft turn a position value of 216 = 65536 pulses is sensed.

On to Step



Anticipated Result

Anticipated Result

Remark, Cause of Fault Condition

The characteristics of the HIPERFACE – Feedback System, as the absolute measuring device (multi-turn provider), allows for 2 additional parameter settings. 1. Selection of the position location, per rotation 16 or 20 bit. 2. Selection of the absolute position value according to the connection between the motor and the mechanical component. Note: It is necessary to initially provide the angular commutation parameter value as the absolute value for the HIPERFACE provider, when employing a motor from another manufacturer with HIPERFACE- Feedback

On to Step



☺ 5



Step 2.5 Motor with SIN-COS Feedback Linear Motor

Action, Function

2.5



Anticipated Result

Remark, Cause of Fault Condition

Additional settings are required with the employment of this variation, which are described in the following section: Step 4.2. Optimization Linear Motors .

On to Step



☺ 5

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8

Commissoning

8.4

Step



: Power Up and Drive Activation

Step 3.1 Power Up Action, Function

3.1.1

1 3.1.2

3.1.3

X60 Connector Assignment

Prerequisite:

Step

+

The power supply is connected to the X60 connection of the 638 Drive. Establish the X60 connection, when lacking, only when the drive system is not connected to the power supply! Terminals 1 and 4 on the X11 STO connection should be set at 0 V.

3.1.4

Turn on the power and check the voltage in the Drive Diagnostic Menu.



Step 3.2 Drive Activation Action, Function

3.2.1

3.2.2

Remark, Cause of Fault Condition

Anticipated Result

It is necessary to make additional settings as described in Step 4.2 Optimization Linear Motor, when employing a motor with a Sin/Cos Feedback system. Terminals 1 and 4 on the X11 STO connection should be set at 24 V.

In the event that no fault condition arises

On to Step



-

In order to eliminate the risk of a short circuit! The drive remains in a nonactivated condition even after the power is connected. The drive will show a DC link voltage Ucc of approx. 325 V DC with an incoming supply of 230 V AC, in a non-activated condition.

X11 Connector Assignment STO = Safe Torque Off 7 Segment Display:

Remark, Cause of Fault Condition

Anticipated Result

In the event that the Feedback System = Sin/Cos On to Step 4.2 Driver – power stage is activated and the 7 segment display shows:

X11 Connector Assignment

The drive is now set in the operations mode (Delivery condition; Speed control set to the analog setpoint)

The motor shaft can be set to turn slower through the 0-V offset setting of the analog setpoint input.

☺ 5

Further function test from the STO – terminal, as per statement in chapter Safe Torque Off. Otherwise 3.2.3

With unanticipated operation or overheating of the motor, turn off the drive and attempt to locate the cause of the problem. Identify and rectify the fault condition. and perform Step

72

again

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Diagnosis and Troubleshooting



8 8.5



Commissoning : Control Loop Optimization

Step

Step 4.1 Control Loop Optimization with Rotary Motors

Action, Function

4.1.1

+

Remark, Cause of Fault Condition

☺ 5

Prerequisite:

Step 4.1.2

Anticipated Result

+

In the EASYRIDER Commissioning Menu select „Speed Controller“

Check the speed and power variation characteristics utilizing an oscilloscope and through the adjustment of the P and I sections set the parameters for the control rigidity.

and with F8=Start the Test Generator.

4.1.3

#

Attach the mechanical component with the motor shaft.

4.1.4

Perform step 4.1.2 again

Pay attention with linear motion! The speed generator is controlled by time and recognizes no parameters unless the limit switch is configured!

4.1.5

Within the EASYRIDER Commissioning Menu select „Position Control“, when employing the position control settings.

Check the speed, power variation and control deviation characteristics utilizing an oscilloscope and through the adjustment of the P, I and V sections set the parameters for the power control rigidity.

Set the position and speed, with F8=Start the Test Generator.

On to Step



☺ 5

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8 ●

Commissoning Step 4.2 Control Loop Optimization with Linear Motors

Step 4.2.1

Action, Function

Anticipated Result

☺ 5

Prerequisite:

Step

+

Remark, Cause of Fault Condition

+

Under Construction!!! On to Step

74

☺ 5



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8 8.6

Commissoning Step

: Operation Mode Selection

Action, Function

5.1

+

+

+

In the EASYRIDER configuration menu, select „General“ and then select the appropriate operating mode.

With the selection of the operating mode, one must also select additional settings. For example: * On/Off Configuration * Analog Setpoint Selection and Integrator * Position Blocks * BIAS Program * Fieldbus Interface

On to Step



Remark, Cause of Fault Condition

☺ 5

Prerequisite:

Step 5.2

Anticipated Result

Additional information and assistance is available through the utilization of the online help for EASYRIDER Software.

☺ 5

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8

Commissoning

8.7

Step

: Fieldbus Interface

Action, Function

6.1

☺ 5

Prerequisite:

Step

+

+

6.2

The overall system commissioning and the communications test of the fieldbus interface are dependent upon the interface configuration of the drive. If there is not an options board connected then there are no more additional settings required, and one can move on to Step 7.

6.3.

In the configurations menu, under „Fieldbus“ additional settings may be required, depending upon the connection interface for the fieldbus board.

On to Step

76

Anticipated Result

Additional information concerning start up procedure for the fieldbus interface connection can be found in the handbook about the Options Board.

☺ 5



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Remark, Cause of Fault Condition

8 8.8

Commissoning Step

: Data Save

Action, Function

7.1

Anticipated Result

☺ 5

Prerequisite:

Step

+

+

+

+

Remark, Cause of Fault Condition

+

7.2

Read the parameters shown in the EASYRIDER Data Menu under „Drive Parameters“.

7.2

In the Menu, under commands select „Save Data on the Drive“

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8

Commissoning 7.3

In the Menu under Data, select „Save As“ , to save the drive parameters on the computer, utilizing the file suffix *.wdd .

First system start up procedure

Steps

+

+

+

+

+

+

successfully accomplished.

78

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☺ 5

9

Safe Torque Off (STO)

9

Safe Torque Off (STO)

9.1

General Introduction The following documentation is meant to provide the basic information concerning our drive controller and an understanding about the advanced, safety oriented machine construction. References to standards or other regulations are made in a general overview manner. The specific standards or regulations for your installation will vary depending upon the equipment employed and the specifics of your application. For more information we suggest referring to specific technical literature, for example: BIA-Report 6/97 and BIA-Report 5/2003 (Information of the German Professional Trade Association). These reports can be downloaded from: http://www.hvbg.de/d/bia/pub/rep/index.html



Important Technical Terms and Explanations

Term

Explanation

Safety Category 3 Performance Level d according to EN 13849-1

Definition according to the regulation: Circuit with built-in protective functions for individual fault conditions. Some, but not all faults will be recognized. The frequent occurrence of fault conditions can lead to a loss of the safety functions. The remainder of the risk must be understood and accepted. The determination for the application of the appropriate safety category requirements, (risk analysis), lies with the installer and operator of the equipment. You can reference the method described in EN13849-1:1996, Appendix B, as an example. Definition according to the regulation The safety related parts must be designed in a way, that a single fault condition in each safety related part will not guide to loss of the safety function and the single fault will be detected before or on next demand of the safety function. If this is not possible, ab accumulation of faults should not a lead to the loss of the safety function. The determination for the application of the appropriate safety category requirements, (risk analysis), lies with the installer and operator of the equipment. You can reference the method described in EN13849-1:1996, Appendix B, as an example.

Safety Category 4 Performance Level e according to EN 13849-1

‚Safe Stop’ or alternatively: ‚Safe Torque Off’ or abbreviated as:

With the activation of “Safe Torque Off“, the energy supply to the drive is definitively interrupted, according to the requirements of EN1037, section 4.1. The drive unit is not allowed to rotate and will therefore not be able to generate any dangerous rotational movements, (See EN 1037, section 5.3.1.3). The stopping position must not be monitored. Should there be the potential of an outside energy source affecting the drive and STO function, for example the dropping of a hanging load, then additional action needs to be taken to guarantee that no additional movement takes place, (i.e. installation of a mechanical brake).

STO

Start-Up Lockout

The following measures are appropriate for incorporation with ”Safe Torque Off”: Protection between power connection and the drive system (Line Fault Protection) Protection between the power unit and the motor (Motor Protection) Protected lock of the control of the solid state power component ( Start-up Lockout) Protected lock of the control of the solid state power component. With help of this function one can establish the activation of the “Safe Torque Off”.

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9

Safe Torque Off (STO)



Stop Category according to EN 60204-1 (Chapter. 9.2.2)

Stop Category

80

Requirement

System Reaction

Note

0

Shutdown by immediate shut-off of power supply to the machines’ driving components

Uncontrolled Shutdown

1

Shutdown, by a means which maintains the power supply connection to the machine drive component, to bring movement to a standstill. The power connection will be broken only after standstill has been achieved.

Controlled Shutdown

Uncontrolled shutdown is the stopping of the machines’ movement by eliminating the power supply to the power components of the machine. Available brakes and/or other mechanical braking systems should be employed. Controlled shutdown is the stopping of the machines’ movement by for example, the setback of the electronic command signals to zero as soon as the stop signal is recognized by the controller, while the power supply to the machine drive components remains intact until a standstill condition is achieved.

2

Shutdown, by a means which maintains the power supply connection to the machine drive component.

Controlled Shutdown

This category will not be covered in the functions description of the manual.

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9 ●

Safe Torque Off (STO) Applications in Accordance with the Regulations The 638 Drive supports the safety function “Safe Torque Off”, in the sense of providing a definitive stopping of the equipment, with protection against unanticipated start-up, in accordance with regulations EN ISO 13849-1, Category 4, Performance Level e and EN 1037. The motor must stopped controlled through the machine controller. However, it does not provide for any verification of cessation of movement which may have been produced from some external source. One must pay specific attention to the vertical axes, without a mechanical self-inhibitor or balanced weight. According to Machine Regulations 89/392/EWG, i.e. EN 292; EN 954 und EN 1050, when considering the safety and risk analysis, the machine constructor is responsible to make certain that the overall safety system for the whole machine takes all of the integrated components into consideration. Note that the electrical drives must also be included in this consideration. One must pay attention to and follow the instructions completely as stated in the validation report, with regard to the initial start-up, service intervals, troubleshooting and repair of the equipment. The STO conformance protocol outlines a suggestion for the documentation of the relevant safety parameters in the validation report.



Trained Personnel Planning, installation and initial system commissioning require a detailed understanding of this information. Protective safety standards and risk mitigation issues which are connected to the specifics of the installation must be recognized and taken into consideration, as well as appropriate actions to be taken in the event of an emergency.



Benefits with the Employment of the Safe Torque Off Function Safety Category 4 performance Level e according to EN 13849-1: Performance Feature Requirement

Application of the Safe Torque Off Function

Conventional Solution : Utilization of External Switching Components

Reduced Switching Effort

Simple circuitry, certified application examples The grouping of multiple drives together on a main contactor is possible. Extremely high switching frequency through the use of almost wear-free technology (Low voltage relays and an electronic switch). The condition “Safe Torque Off” is achieved through the use of a wear-free electronic switches (IGBT’S).

Two safety-oriented performance protections in series connections required.

The drive remains power and control related in a connected condition. No significant wait time with re-start.

With the utilization of power contactors on the incoming power line, a long wait time is required for the energy discharge from the DC link.

Application in Production Processes High Switching Frequency, High Reliability, Less Wear Application in Production Processes Faster Reaction Time, Faster Re-Start

Emergency Stop Function

According to the German Edition of the Standards: Permissible without mechanical power switch element activation 1)

This performance feature is not achievable through the employment of conventional technology.

With the use of two motor side power contactors, it is possible to increase the reaction time, however one must recognize the potential disadvantages:: a) Make certain that switching occurs only in a power free condition, (DC Power! Prevent arcing). b) Increased cost for EMC conforming cabling. Shutdown employing a mechanical switching element is required.

1) According to the forward of the German edition of the standards EN 60204-1/11.98, electronic equipment for use with the emergency stop mechanism is acceptable, as long as the requirements in the safety categories, like those required in EN13849-1, are completely observed.

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Safe Torque Off (STO) Safety Instructions and Limitations No Galvanic Separation of the Outputs The galavanic separation does not occur through the starting lockout function. This therefore does not in any way provide protection against an “electrical spike”. For operation interruptions, maintenance, service and cleaning of the equipment, the entire system must be definitively and galvanically separated from the power supply at the main switch box and confirmation should be made that the system can not restart (See EN 60204-1;5.3). Potential Sudden Jerking or Movement under Fault Condition In the event that two fault conditions appear at the same time in the power unit, it is possible that unit may exhibit a sudden jerking or movement within a small angle of rotation. This is dependent upon the number of pole pairs of the motor. (Rotary Type:2-pole = 180°, 4-pole = 90°, 6-pole = 60°, 8-pole = 45°; Linear Motors: 180° electric). Malfunction during the Active Braking Phase with Stop Category 1; EN 60204-1 (controlled stop with reliable monitored time delay) If a fault in the drive system occurs during the active braking phase, the axel can coast to a stop, uncontrolled or in the worst case continue to operate until the expiration of the predetermined shut-off time. Hanging Loads or Influencing External Forces In the event of a power failure the hanging loads can possibly fall in an uncontrolled manner endangering people or equipment. The operation of hanging axes therefore requires special attention relating to risk analysis and mitigation with hanging loads. Not for Use in Drive Applications in Field Weakening Operation Ranges! With motors which are employed in field weakening operation ranges, it is important to note that the operation of the STO function can be adversely affected, specifically involving an uncontrolled increase in rotational speed, life threatening over voltage and explosion of the drive unit! Minimal request of safety function The safety function STO must activate for at least weekly.

Acknowledgement The configurable acknowledgement is only permissible with category B.

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9 9.2

Safe Torque Off (STO) Safe Torque Off Function, (STO) General The electricity flow to the motor windings is controlled through a solid state power component bridge (6-times IGBT). A microprocessor switch with PWM logic switches the IGTB’s rotating field orientation. Optical couplings are employed between the control logic and the power unit to provide for electrical isolation.

The X11 Connector Plug (STO) is located on the front of the drive unit. This connector plug is controlled utilizing two optical couplings which communicate over two channels through terminals STO1# and STO2#, and which in a controlled condition supplies the PWM optical coupler with control of the solid state power component. A test takes place to determine the condition of the input channels. Within the given window of time the condition of both channels must be identical. In the event that a fault condition exists, (different signals from STO1# and STO2#), then the coupling power supply is shut-off and a signal is sent to the 7 segment display. The re-activation of the power supply to the coupling is then only possible by performing a hardware reset, by turning the equipment off and then back on again. In addition to the description of the hardware based shut-off through the two channel communication, the internal unit processor provides for a software based shutdown of the PWM circuit. The PWM circuit can be set for time delayed activation, after the recognition of the activation of both STO inputs, through the programming of the safety parameters for the active time delay.



Block Circuit Diagram

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9 ●

Safe Torque Off (STO) Status Diagram and Function of Terminals STO1# und STO2# • With hardware monitoring of the contact difference between STO1# und STO2# (Tolerance - ca. 20 Sec.) • Active Time Delay tva > 0 • No additional special functions

Diagram: Flow chart of the switching status from STO1# and STO2# Note for Standard Operation: • The STO inputs should always be operated simultaneously. If the safety parameter Active Time Delay is tva = 0 s, then both STO inputs will be turned on immediately after recognition.

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9 9.3



Safe Torque Off (STO) Configuration and Parameter Settings General Instructions for Parameter Settings The safe torque off, ’STO’, basic function is a built-in, hardware oriented safety function which is not configurable. Depending upon the specific application however, it is possible to alter specific settings on the drive side which can increase the operational safety factor. The configuration and programming of the safety parameters can be accomplished utilizing the Diagnosis and Parameter Setting screen in EASYRIDER for Windows. This configuration process has been designed to assist the user in making the proper parameter settings, in an attempt to eliminate the potential for systematic programming errors and/or improper parameter settings.

Required Actions for the Configuration of Relevant Safety Parameters • •

• • • •

Special password protected access is required to reach the relevant safety parameter setting screens. The transmission of the data through the PC interface follows a specially designed protected procedure, including: CRC check, drive specific password and a double confirmation and acknowledgement process for the parameter values entered. After the confirmation and acknowledgement of the entered data, the parameter values are saved in the drive and protected even in the event of a power loss. The parameter values are stored twice within the drive, and provide for automatic periodic verification of the memory cell accordance. Any other means of accessing the safety and security related data, as described here, is not permitted. The creation of a parameter protocol, which can be stored as a document with appropriate name and date information.

The relevant safety, secondary function parameters – Acknowledgement and Active Time Delay, can only be set within the Configuration Safety dialog box. The data are saved under Parameter Data utilizing the suffix *.WDD. But the safety relevant data will not transmit by “Transmit Parameters”.

In the Configuration Safety dialog box the relevant safety parameters will shown by an open parameter file. The user has to transmit the parameter safely to the drive.

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9 ●

Safe Torque Off (STO) EASYRIDER Safety Parameter Data Entry Dialog Boxes 1. Commissioning menu - select “Safety“ :

2. Access password - enter “BGSM“

and verify with “OK“

3. Enter Safety Password, select Parameter Nr. and enter the appropriate Value

4. Send the Parameter - press “Send”one time

4. When the yellow display is correct - press the “Acknowledge” button twice to accept

5. When the parameter display is green, it confirms that the value is correct, has been stored and power loss protected in the drive unit! Once all of the relevant safety data parameters have been entered, then it is possible to call up the protocol form of the actual safety parameter settings by pressing the “Protocol file” button. (ACROBAT Reader is required!) Note: A copy of the Safety-Parameter-Protocol Form is available in the appendix of the Servo Drive Handbook and can be used for verification purposes.

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9 ●

Safe Torque Off (STO) Safety Parameter List The following safety functions are presently able to be configured: • • •

Parameter 0: Function Input X10.22 Parameter 1: Active-Time Delay Parameter 2: STO-Power-On-Test

Parameter 0

Value Range Without Function

Acknowledgement + Emergency Stop

Function X10.22

Acknowledgement

Emergency Stop

Parameter 1

Explanation No safety relevance. Function X10.22 is freely programmable (BIAS) Initial Factory Settings (default values) STO-function activation through additional low high edge of the X10.22 input acknowledgement and Emergency Stop before the STO shutdown through additional high low edge of the X10.22 input. STO-function activation through additional low high edge of the X10.22 input acknowledgement. Before the STO shutdown through additional high low edge of the X10.22 input.

Note

Flow Chart

See below

After the recognition of the edge – the active time delay will be started! After the recognition of the edge, when the rotational speed =0 then the emergency stop ramp will be executed and when the rotational speed =0, the time delay for the brake will be started!

Value Range 4 Initial Factory Settings (Default Value) Active-Time Delay 4- 500 (*10 ms) (in 10 ms increments)

Explanation Time delay for the activation of the final stage after acknowledgement (24 V) of both STO inputs, for example of the acknowledgement inputs (in the event that they have been configured).

Parameter 2

Explanation The STO-Power-on-Test does not allow by deactivated STO (STO1# and STO2# High) to activate the drive. The 7-Segment-Display shows . The drive will able to activate after the safety function STO was activated and is deactivate. The safety function could activated by a safety gate or an emergency stop It is possible to use a PLC to automate this test.

Note: If the STO inputs, for example, the acknowledgement inputs are removed (0V) before the expiration of the active time delay, then the time will be reset and only reactivated with a new edge (24 V).

Value Range activate (0),(default)

STO-Power-OnTest

deactivate (1)

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Safe Torque Off (STO) Safety Password The safety password must be entered in the appropriate field, every time that the Safety Parameter Configuration screen is selected. The password is always comprised of 4 letters. The difference between large and small case letters is recognized. The drive side initial factory setting of the password is “SAFE“. The responsibility to set the new safety password lies with the operator of the equipment. The new safety password should only be shared with authorized personnel, for example: anyone who works on the STO, and/or has responsibilities in the areas of equipment operating guidelines or equipment safety and security. Flow Chart Diagram: Function X10.22 Acknowledgement + Emergency Stop

Flow Chart Diagram: Function X10.22 Acknowledgement

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9

Safe Torque Off (STO) Flow Chart Diagram: Function X10.22 Emergency Stop

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Safe Torque Off (STO)

9.4

Application Example of STO (Safe Torque Off) Example

Function

Application Example 1

Safety door monitoring or emergency shut-down with protection monitoring switch Safety door monitoring or emergency shut-down with protection monitoring switch and time delay Safety door monitoring or emergency shut-down WITHOUT protection monitoring switch Safety door monitoring or emergency shut-down with protection monitoring switch and time delay of several drives

Application Example 2 Application Example 3 Application Example 4

Minimal request of safety function (from Cat. 3 and PL d) The safety function STO must activate for at least weekly. This request is very important for application continuous operation and is satisfy by open the guard door and activate the emergency stop. If the Safe torque off is activate very often, additional measures are not necessary. (Only if the Guard door and/or the emergency stop is connected directly or via safety unit at the 638 X11). Additional Minimal request of safety function by Cat. 4 and PL e The category 4 and PL e can only be attained if the STO-power on test is enabled. The STO-power on test needs low-level at both STO# inputs by switch on the 24V control voltage. The drive can not activate if one or both STO-inputs have high-level. The function must configure in the Safety-Dialog parameter 2 (default Active). These minimal requests are necessary to detect a failure. Failure detection is only possible if the safety function is activated. Both measures could execute by a PLC.

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Safe Torque Off (STO) Application Example 1 Function/Action

Response

Protection Level EN 954-1

Safety door monitoring or emergency shut-down with protection monitoring switch

The ‚STO’ is tripped when the safety door is opened or emergency shutdown switch is activated.

Cat. 4

ISO 13849-1

Stop Cat. According to EN60204

PL e

0

Important The category 4 and PL e protection level can only be achieved with an active STO-Power-On-Test. Note The acknowledgement is only necessary, when after the cancellation of the STO function by the automatic start-up, a potential danger for the people in the area or the equipment exists.

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Safe Torque Off (STO) Application Example 2 Function/Action

Response/Reaction

Protection Level EN 954-1

Safety door monitoring or emergency shut-down with protection monitoring switch and time delay

Active braking occurs when the safety door is opened, the emergency shutdown switch is activated or tripping of the ‚STO’ occurs due to time delay.

Cat. 4

ISO 13849-1 PL e

Stop Cat. According to EN60204 1

Important The category 4 and PL e protection level can only be achieved with an active STO-Power-On-Test. Explanation The protection switch unit A1 must be set up with a fail-safe time delay as determined and required by the specific category relating to the application environment. The 638 Servo Drive must be properly configured for the operating environment (See: Chapter ■ Configuration and Parameter Settings). Note The acknowledgement is only necessary, when after the cancellation of the STO function by the automatic start-up, a potential danger for the people in the area or the equipment exists.

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Safe Torque Off (STO) Application Example 3 Function/Action

Response/Reaction

Protection Level EN 954-1

Safety door monitoring or emergency shut-down WITHOUT protection monitoring switch

The ‚STO’ is tripped when the safety door is opened or emergency shutdown switch is activated.

Cat. 3

ISO 13849-1 PL d

Stop Cat. According to EN60204 0

Explanation The signals for STO1# and STO2# are delivered utilizing two separate channels. The wiring layout plan must allow for the physical separation of the wiring channels or incorporate adequate insulation protection and separation. Note The acknowledgement is only permissible with category B. The acknowledgement is not permissible for use if the dangerous area is accessible. In this case, employment of an external acknowledgement unit is necessary. The acknowledgement is only necessary, when after the cancellation of the STO function by the automatic start-up, a potential danger for the people in the area or the equipment exists.

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Safe Torque Off (STO) Application Example 4 Function/Action

Response/Reaction

Protection Level EN 954-1

Safety door monitoring or emergency shut-down with protection monitoring switch and time delay of several drives

Active braking occurs when the safety door is opened, the emergency shutdown switch is activated or tripping of the ‚STO’ occurs due to time delay.

Cat. 4

ISO 13849-1 PL e

Stop Cat. According to EN60204 1

Important The category 4 and PL e protection level can only be achieved with an active STO-Power-On-Test. Explanation The protection switch unit A1 must be set up with a fail-safe time delay as determined and required by the specific category relating to the application environment. The 638 Servo Drive must be properly configured for the operating environment (See: Chapter ■ Configuration and Parameter Settings). Only 16 drives could plug together in a group. Note The acknowledgement is only necessary, when after the cancellation of the STO function by the automatic start-up, a potential danger for the people in the area or the equipment exists.

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Safe Torque Off (STO)

9.5

STO Function Test The STO function must be tested when: • The system is set-up for the first time. See: Commissioning • Any component of the system is replaced. • Any activity involving the wiring takes place. • After all modifications to the drive system. (For example: parameter modifications, software updates, etc.) • Established maintenance schedules dictate or after the machine has been inactive for a long period of time. The STO functions test must be carried out by qualified personnel, with consideration for the required safety provisions. Depending upon the system configuration and application, additional or other tests may be required. Test Steps: STO Test Step 1 STO Test Step 2 STO Test Step 3 STO Test Step 4 STO Test Step 5

STO-TEST Step

STO-TEST 1.1

Action / Function

STO-TEST 1.3

STO-TEST Step

STO-TEST 2.1

STO-TEST 2.2

STO-TEST 2.3

STO-TEST 2.4

Remark, Cause of Fault Condition

Prerequisite: 1.1.1 Safety Parameter: STO “Power On” Test is Active 1.1.2

STO-TEST 1.2

Anticipated Result

Supply Voltage US = 0 V (off) If the safety parameter, “Start-up Test” – is deactivated, then the drive will be activated immediately after the switch is turned on!

24V DC Voltage to Terminal X11.1 and Terminal X11.4

Supply Voltage US = 24 V to the System

Action / Function

Test steps 2-4 can then be performed anyway.

Anticipated Result

Terminal X11.1 Test: Switch off 24 V DC Voltage at terminal X11.1 Wait approx. 20 seconds

After approx. 20 seconds

Switch on 24 V DC Voltage at Terminal X11.1

Remark, Cause of Fault Condition

flash

Check 7-SegmentDisplay Check 7-SegmentDisplay

flash Software-STO control mechanism successful Hardware- STO control mechanism successful

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95

9 STO-TEST Step

STO-TEST 3.1

STO-TEST 3.2

Safe Torque Off (STO)

Action / Function

Terminal X11.4 Test: Rebuild STO Test Step 1

Anticipated Result

Remark, Cause of Fault Condition

Switch the 24V Supply Voltage Off On

Switch off 24 V DC Voltage at Terminal X11.4 flash Wait approx. 20 seconds

STO-TEST 3.3

Check 7-SegmentDisplay flash

STO-TEST 3.4

STO-TEST 3.5

STO-TEST Step

STO-TEST 4.1

STO-TEST 4.2

STO-TEST 4.3

STO-TEST 4.4

STO-TEST Step

STO-TEST 5

96

After approx. 20 seconds

Check 7-SegmentDisplay

Switch on 24 V DC Voltage at Terminal X11.4

Hardware- STO control mechanism successful

Action / Function

Terminal X11.1 and Terminal X11.4 Test: Rebuild STO Test Step 1

Software-STO control mechanism successful

Anticipated Result

Remark, Cause of Fault Condition

Switch the 24V Supply Voltage Off On

Switch Off 24 V DC Voltage at Terminal X11.1 and Terminal X11.4 Wait approx. 20 seconds

After approx. 20 seconds Switch on 24 V DC Voltage at Terminal X11.1 and Terminal X11.4

Check 7-SegmentDisplay If the drive has no fault and no other switch off condition is set - then the drive is activated.

Action / Function

Once all of the relevant safety test steps have been accomplished, the actions taken must be documented. The protocol form can be found in the Appendix ■ STO - Safety - Parameter - Report - Proposal.

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9 9.6

Safe Torque Off (STO) Signal Inputs Technical Data - Terminal Connection X11 General

Nominal Voltage from the Inputs Required Insulation from the Control Voltage 24V STO – Control Voltage Protection Number of Inputs Signal Inputs via Opto-Coupler

STO1# STO2# Break Time at Unequal Input Conditions Function see Status Diagram

The technical data provided in the section General Technical Data is valid, with the exception of the data listed below. 24 V DC protective extra-low voltage (PELV) 1A 2 L = 0...7 V DC or open H = 15...30 V DC Iin at 24VDC: 8 mA L = STO activate H = STO deactivate L = STO activate H = STO deactivate approx. 20 seconds

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97

10

Diagnosis and Trouble-Shooting

10

Diagnosis and Trouble-Shooting

10.1

7-Segment-Display Many sources of faults can be narrowed down with the diagnosis display.

Display (Code)4 00h

Output

Explanation Comment

Servo drive

Ready Warnin 631 g2)

no display

off

off

on

off

on

off

off

off

off

off

deactivated via input.

on

off

deactivated via serial command.

off

off

Active input is activated with switching on 24 V control voltage

off

off

635/637

637+

637f/638

X10.22

X10.2 2

X10.22

any control voltage? external fuses ok? 03h

system ready for operate drive ready, not active

01h

drive active and ready for operate! DC link voltage within the limits, power stage active, fault-free

12h

internal STOP with serial deactivating activate drive via serial interface

82h

drive of serial interface (bus interface) deactivated ! only if bus interface is integrated

90h

92h

deactivated with delay time for the brake

X10.7

switch enable X10.xx switch on 0 V and after that 24 V 46h

Under voltage of control voltage

off

off

off

off

off

off

off

off

Power supply switched on? Power supply o.k ? internal fuse o.k.? control voltage < 17 V 60h

Under voltage in DC-bus < Ua low threshold check power supply (power supply unit, wiring, fuse), check under voltage parameter

DAh

feedback system error (e.g. resolver) wiring to encoder system ok? encoder system supply ok?

DAh 00h

„flashing“ Resolver - Feedbacksystem Error

8.36

wiring to resolver system ok?

98

DAh

„flashing“ HIPERFACE Feedbacksystem Error

6Eh

wiring to HIPERFACE system ok? Check serial HIPERFACE channel

off

off

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8.36

10

Diagnosis and Trouble-Shooting

Display (Code)4 F2h

Output

Explanation Comment

Ready Warnin 631 g2)

I²t- overload of the drive

1)

1)

1)

1)

1)

1)

1)

1)

off

off

on

1)

off

1)

on

1)

on

off

on

on

off

off

off

off

Servo drive 635/637

637+

637f/638

does the control loop oscillate? P-amplification too high mechanics stiff? requirements too high? is warning /8/ evaluated? 66H

I²t overload of the motor does the control loop oscillate? P-amplification too high mechanics stiff? requirements too high? is warning /8/ evaluated?

B6h

over temperature of the output stage (> 90°C) adequate cooling of the regulator? ambient temperature too high?

3Eh

over voltage on DC bus ballast module ok? adequate ballast module?

E0h

chassis shorting and short circuit due to hardware motor cabling ok? digital-loops setup ok? short circuit to chassis in the motor? braking resistor: ohm- value too low? try to start fresh! send in for repair

FEH

WARNING! Overload of the regulator I²t or motor I²t or temp.output stage too high. If no reaction within approx. 3sec.it switches off with signals /3/, /4/ or /5/. Signal /8/ clears when there is no more danger or it is switched off mechanics stiff? defective bearings; cold grease? reduce requirements and creep to next possible STOP

F6h

over temperature motor(NTC/PTC) check overload of the motor / cooling etc.

2Eh

motor temperature too high check overload of the motor / cooling etc.

80h

ballast active Brake energy is removed

38h

Warning: I²t ballast too high ballast resistance usage >90%

7Ch

switch off ballast ballast resistance overloaded

6Ch

X 300 – Module not inserted or wrong inserted or defect X 300 testing

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99

10

Diagnosis and Trouble-Shooting

Display (Code)4 6Eh

Output

Explanation Comment

Servo drive

Ready Warnin 631 g2)

off

X 300 – setting wrong

635/637

637+

637f/638

X10.8

X10.14

X10.1 4

X10.14

X10.9

X10.15

X10.1 5

X10.15

X10.8 X10.9

X10.14 X10.15

X10.1 4 X10.1 5

X10.14 X10.15

off

X 30 / X40 Counter-Configuration test in the EASYRIDER® Windows – Software 1Ch

tracking window exceeded 3)

on

only in operation mode position control, will be deleted with the next run-command 1Eh

tracking error with switch off

on

off

on

off

only in operation mode "position control" 20h

limit switch + 3) limit switch + X10.xx on 0 Volt, from Firmware 6.16

08h

on

limit switch - 3)

off

limit switch - X10.xx on 0 Volt, from Firmware 6.16 3) 9Eh

limit switch + / limit switch -

on

off

both limit switch X10.xx on 0 Volt, from Firmware 6.16 76h

memory-checksum-error

off

off

aus

aus

off

off

on

off

off

off

try new start, store the value again 76h

Different Drive type on X300-xM Module

62h

DC Bus Unterspannung < 100 V

638 with X300 xMModule only

4Eh

1: internal software error, Watchdog 2: blinking: BIAS software error 1: Firmware version check 2: Bias program error fix

EEh

starting lockout RP SBT with 637f starting lockout STO1 and STO2 with 638 Terminal X290. 3/4 check with 637f TerminalX11. 1/4 check with 638

24h

STO1 und STO2 Signale Difference>20 Seconds Switch Off /On Control Voltage

100

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638 only

10

Diagnosis and Trouble-Shooting

Display (Code)4 26h

Output

Explanation Comment

Servo drive

Ready Warnin 631 g2)

X10.22 Quickstop Ramp active

on

635/637

637+

637f/638

off 638 only

42h

X10.22 low high slope missing

on

off 638 only

2Ah

Max. speed overload

off

off

on

off

check speed limits resp. setpoint speed 4Ah

CAN - Open 402 Sync Message error in Interpolated positioning mode

6.19c

8.19d

9Ch

on

SSI – Encoder Error

off 8.21

9Ch

1Ah

CAN1-BUS Error Flashing display Noise on bus or lane missing!

on

off 8.33

CAN2 Bus Error 8.36

Flashing Display: Control loop synchronization between drives CEh

on

Profibus-Module Error

off 8.31

ECh

30h

Warning:setpoint current maximum limit reached and no actual current measurement (check motor connection)

on

638 Active Delay time runs

on

off 8.34

off 638 only

8Eh

638 SAFETY- Parameter Ram Error

off

off 638 only

C4h

638 X300 xM Module, Memory Error Firmware, Alteracode and Parameters missing

off

off

44h

638 X300 xM Module, Memory Error Alteracode and Parameter- and BIAS-Data missing

off

off

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638 only with X300 xMModule

101

10

Diagnosis and Trouble-Shooting

Display (Code)4

Output

Explanation Comment

Ready Warnin 631 g2)

04h

638 X300 xM Module, Memory Error Alteracode missing

off

off

40h

638 X300 xM Module, Memory Error Parameter- and BIAS-Data missing

off

off

1) 2) 3) 4)

Servo drive 635/637

637+

Reaction to these errors chapter: “■ Function diagrams from inputs and outputs” With configuration corresponding chapter : “■ Operating modes and pin functions” Operating mode “Position Control” only The display code you can get with the serial command „internal diagnosis 2“ (0x26) in byte 16.

The error signals are shown as long as there is control voltage (Us), also when the power (DC-Bus) is switched off for safety reasons.

102

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637f/638

10 10.2

Diagnosis and Trouble-Shooting Reset of a Drive Trouble A general precondition for correct execution of the Reset is the elimination of the error cause.

Possible error signals at blinking (BIAS)

The error signals of the drive can be reset via: 1. Control voltage OFF/ON, 2. the serial command “Drive Reset“ 0x02 The host login must be occurred. The drive must be deactivated via the serial command “deactivate Drive“ 0x00. 3. the fieldbus-command “ Drive Reset“ 0x16 (22 decimal) The host login must be occurred via the BUS command 0x01.The drive must be deactivated via the BUS command “deactivate Drive“ 0x14. The fieldbus command “Drive Reset“ with constant repetition of the fieldbus command 0x16 will be works-off only once. For further processing, it is necessary, meanwhile to send another control word (e.g. 0 status order). 4. Viva 0 – 1 flank on input X10.11 Precondition: - The input X10.11 is with function 1“Reset drive fault“ configured (EASYRIDER® Windows – Software) - There is no host login. - The input Active,(X10.22) is inactive (0V) - The signal must be present min. 250 ms 5. Viva 0 – 1 flank on input X120.1 Precondition: - The input X120.1 is with function 1“Reset drive fault“ configured (EASYRIDER® Windows – Software) - There is no host login. - The input Active,(X10.22) is inactive (0V) 1) - The signal must be present min. 250 ms

Notice !! After remove of the tracking error deactivation the warning message (tracking error) is active up to the next move command.

The error signal

(releasing before ready) can be reset by deactivation the drive.

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103

10

Diagnosis and Trouble-Shooting

10.3

Trouble-Shooting The following list refers to faults which can occur during operation. Display:

Error

Explanation and remedy

no motor run despite current flow

motor mechanically blocked? motor brake released? check setpoint wiring check grounding and shielding too high P-amplification in the speed controller reduce value (with EASYRIDER® setting/speed control) too small I-time in the speed controller? reduce value (with EASYRIDER® setting/speed control) Limit switch functions effective (BIAS) motor cables interrupted? Is input "I extern" (X10.19) activated (config. menu) and not notched up?

motor runs unevently

no reaction of setpoint progression, despite torque in standstill no current flow; no torque despite activating the regulator correctly

1)

limit switch - input activated and not notched up? Interference symptoms with power Ground loops in setpoint or actual value wiring? frequency Shieldings laid on both sides? Signal cables near high voltage cables? Motor takes up preferred positions after Position encoder or motor cables with reversed activation poles? Resolver or Feedback- encoder incorrectly adjusted? Number of motor poles wrong matching? (config. menu) Motor runs up immediately after activation Motor cables or feedback- cables reversed? although there is no setpoint Encoder incorrectly adjusted? (e.g. Resolver) Motor reaches in idling cycle very different Feedback-Encoder incorrectly adjusted speed when running to the right or to the left (e.g. Resolver) 1) Display

104

or

mostly short after activating; before warning

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1)

1)

11

Standards and Certifications

11

Standards and Certifications

11.1

Compliance with Regulations, Limitations and Basic Conditions European Directives In accordance with EN61800-5-1 Safety requirements – Electrical, thermal and energy. EN 61 800-3, Emissions and immunity levels for Power drive systems.

EG Low-Voltage Guidlines 2006/95/EC EG-EMC-Directive 2004/108/EC

UL - Approved / being prepared Underwriter Laboratory Standard UL File-No. Canadian Standards Association

UL 508 C E…. C22.2 No.14

Power Conversion Equipment Industrial Control Equipment

Insulation Requirement EN 50 178 IEC 60364-4-443:1999 EN 61800-2, 4.1.2.1

Protection Class Overvoltage Category Pollution Degree

I III 2

Environmental Conditions General Environmental Ambient Temperature Rating: Operations Storage Transport Allowable Humidity: Operations Storage Transport Vibration:

Air Pressure Protection Altitude

Method of Cooling

EN 61800-2 IEC 60721-3-3 IEC 60721-3-3 IEC 60721-3-2

+ 5 bis +40 °C, 3K3 -25 bis +55 °C, 1K4 -25 bis +70 °C, 2K3

IEC 60721-3-3 IEC 60721-3-3 IEC 60721-3-2 EN60068-2-6 Test FC

24V): Damping of the Transfer from High to Low (24-->0V)

108

24 V DC +20% / -10% 4 resistive load Imax. = 2A inductive load max. 1Henry Iout. Inductance Max. Switching Frequency 1A 1H 1Hz 1A 0,1H 10Hz 0,33A 1H 10Hz 0,2A 0,5H 50Hz short-circuit current limited by (5A) over-heating protection, active overvoltage clamping (50V); keyed 4 L = 0...7 V DC or open H = 15...30 V DC Iin at 24VDC: 8 mA > 1 ms default input: 200µs default input: 1000µs

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12 ●

Technical Data Digital Control Current Control Loop-Cycle-Time Settings Current Limits - Adjustment by:

105 µs according to factory specifications or motor data speed control -menu Analog Input 0..10V = 0..100%; can be standardized, 10Bit

Speed Control Loop-Cycle-Time Settings Differential Setpoint Input Analog Resolution (including sign)



Digital Setpoint Input

105 µs speed control menu Usoll = 10 V, can be normed; Ri = 10k 14 bit via interfaces

Position Control Loop-Cycle-Time

105 µs

Digital Communication RS232 - Service Interface

COM1 19200 baud, 8 data bits, 1 start bit, 1 stop bit, parity: even

Optional RS232 / RS422 / RS 485 on SUB D – Socket CAN1, Profibus DP, SUCOnet K on SUB D – Socket Interbus S on SUB D – Socket (OUT) Interbus S (Remote IN) CAN2



COM2

additional on SUB D – socket

Resolver Evaluation / Transmitter Principles General: The specified data refers to the combination of the standard resolver interface with Function Module - X300_RD2; operated with the SSD Drives Resolver R 21-T05, R15-T05 Carrier Frequency Ripple of the Actual Speed Value Signal Max. Position Resolution for One Revolution Absolute Position Accuracy Relative Position Accuracy 1)

ft = 4,75 kHz 2% 1) 65536 / 16 bit +/- 0,7 ° 1) +/- 0,08 ° 1)

Data was checked – actual data results: Quality improved

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109

12 ●

Technical Data Controller System System Start-Up Time after Switching On the Control Voltage Data Memory / Organization



Flash Eprom 256 KB RAM 64 KB; EEPROM 96 kByte

Mechanical Data Dimensions

Weight

110

max. 6 seconds

see “■ Dimensions“ 638A 638B03 638B08 /05 /10/15 1,6 Kg 2,7Kg 4,4Kg

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638C

12 12.2 ●

Technical Data Technical Unit Data 638A

Servo Drive Input Supply Voltage 50..60 Hz (grounded at the centre point TN networks) Phases Supply System Inrush Current Limitation Control Voltage Control Current Incl. Fan Permanent: Inrush peak: Output Sine Voltage with Un Derating of Unr Rated Current Efficiency Max. Current Efficiency Time for Imax Min. Motor Inductance (terminal / terminal) Brake Circuit Operating Point DC Max. Power Rated Power Internal Brake Resistor

Min. Ext. Brake Resistor General Power Loss Fan, Electronics Fan Control Power Loss Rating Class per A 1) 2)

638A01..

1)

2)

638A04..

638A06..

min. Un max.

[V] [V] tolerance

type Us Is DC

[V]

14 230 +10% 1 or 3 “■ Fuse, Contactors, Filter“ Softstart : capacitor - pre-charging over 390Ω 21,5 ... 24 … 29

[A] [A/ms]

nominal 0,4 maximum 0,8 nominal 3 maximum 6/0,8; 2,5/25

Unr

[Veff]

Inr Imaxr Lph/ph

[A] [A] Sec [mH]

220 Depending on load or with 1-phase supply 1 2 4 6 2 4 8 12 5 5 5 5 10 6 3 2

Ub Pbmax Pbnenn Rbint Pd Pmax Rbextmin

[V] [kW] [W] [Ω] [W] [W] [Ω]

375 5,5 600 170 20 830 33 (use only our approved types)

max.

[W]

17

[V]

2-stage control

[W/A]

7 (4,75kHz) / 9 (9,5kHz

1)

2)

638A02..

nominal

Reference “● Output Power“ Recommended: Transformer power supply

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111

12 ●

Technical Data Output Power 638A In the event of continuous operation in the full-load range, the limits as shown in the following diagram need to be respected. Typical servo applications are not affected by this restriction. (S3 operation: Start/Stop).

1) At servo drive 638A/06.. : Load limitations decreased to 66% with 1phase incoming supply and continuous operation and speed. (S1)



Singlephase and Threephase supply Due to the line-ripple of the DC-Bus, the rate of usable output voltage is reduced as follows. This reduction affects the maximum attainable speed of the applied motor. Three-phase supply: The unloaded output voltage will be reduced to approx. 90%, maximally 85 % Single-phase supply: 50 – 60Hz: see following Diagram:

Hint for Parameterization: To avoid the unexpected tripping of the under voltage threshold, the parameter setting should be left on the default values (EASYRIDER® Windows – Software). Required motor-terminal-voltage for specified speed. Approximation: (up to 3000RPM) Ukl = 1,2 * (EMF * n / 1000) + I * (Rph + RL) [V] Ukl Required Motor Voltage [V RMS] EMF Back-EMF of Motor [V RMS] / 1000 RPM Rph Resistance of Motor (between terminals) [Ω] RL Line Resistance of Motor cable [Ω] I Motor Current [A RMS]

112

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12 ●

Technical Data 638B

Servo-Drive

638B03..

Input Supply Voltage 50..60 Hz (grounded at centre point TN – networks) Phases Supply System Inrush Current Limitation Control Voltage Control Current nominal/maximal Control Current Inrush peak: Output Sine-Voltage with Un Minderung von Unr Rated Current 400V AC/ 4,75kHz Rated Current 400V AC/ 9.5 kHz Rated Current 480V AC/ 4,75kHz Rated Current 480V AC/ 9,5kHz Max. Current efficiency Time for Imax Min. Motor Inductance 4,75kHz 400 / 480V AC Min. Motor Inductance 9,5kHz 400 / 480V AC Brake Circuit Operating Point DC Max. Power 400/480V AC Rated power Internal Brake Resistor 400V / 480V AC min. ext. Brake Resistor 400/480V General Power Loss Fan, Electronics Fan Control Power Loss Rating Class per A 1) 2)

min. Un max.

3)

1)

4)

638B08..

638B10.

638B15..

[V] [V] olerance

14 400 /480 -25% / +10%

type Us Is DC Is DC

[V] [A] [A/ms]

3 “■ Power Mains Connection“ Softstart : capacitor – pre-charging over 340Ω 21,5 ... 24 … 29 0,6 / 1,0 0,7 / 1,1 0,8 / 1,2 nominal 3 maximal 6/0,8; 2,5/25

Unr

[Veff]

Inr Inr Inr Inr Imaxr minimal

[A] [A] [A] [A] [A] Sec

Lph/ph

1)

2)

638B05..

[mH]

2,5 2,5 2,5 2,5 5 5 8,9 / 10

388 / 465 According to the load 1) 5 7,5 10 5 7,5 10 5 7,5 10 4,5 6,8 9 10 15 20 5 5 5 4,5 / 5,0 3,3 / 3,0 2,2 / 2,5

15 10 14,5 9 30 5 1,5 / 1,7

Lph/ph

[mH]

4,4 / 5,0

2,2 / 2,5

0,7 / 0,8

Ub Pbmax Pbnenn Rbint Pd Pmax

[V] [kW] [W]

6,5 / 7,4

Rbextmin

[Ω]

680 15 670 / 849 78 / 88

maximal

[W]

24

[Ω] [W] [W]

[V] nominal

[W]

1,5 / 1,7

675 / 760 9,8 / 10,9 1100

54 / 62

26,4

1,1 / 1,2

22 / 25,5 330 30 1380 / 1750 22/24

22/24

28,8

24 11,5 (400V/4,75kHz), 15,8 (400V/9,5kHz), 11,8 (480V/4,75kHz), 16,8 (480V/9,5kHz)

Reference “● Output Power 638B“ Recommended: Transformator power supply

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113

12 ●

Technical Data Output Power 638B In the event of continuous operation in the full-load range, the limits as shown in the following diagram need to be respected. Typical servo applications are not affected by this restriction. (S3 operation:Start/Stop). At mains voltage 400V no restriction of the output power on the devices withstands 5 / 7,5 / 10A.

480V Netzspannung: 5A / 7,5A / 10A 2

> 5 sec

1,8 1,6 > 10 sec Imaxr/Inr

1,4 > 20 sec

1,2 1

480V 4,75kHz 480V 9,5kHz

0,8 0,6 0,4 0,2 0 0

80

160

240

320

400

480

Output Voltage [V]

400/480V Netzspannung: 15A > 5 sec

2 1,8 1,6

> 10 sec

Imaxr/Inr

1,4

> 20 sec

1,2

400V 4,75kHz

1 0,8

400V 9,5kHz

0,6

480V 4,75kHz 480V 9,5kHz

0,4 0,2 0

0

114

80

160 240 320 Output voltage [V]

400

480

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13 13

13.1

Software Software

EASYRIDER® Windows - Software

EASYRIDER® Windows software is a useful and convenient tool to use to control all drive functions. Detailed online help information and instructions are available.

EASYRIDER® Instructions: (extract) Auto pilot function as an interactive tutorial System identification BIAS instruction-set editor Oszilloscope function Start-up and commissioning tools Setting of parameters and setting of configurations Servo diagnostics, interface diagnostics and fieldbus diagnostics Motor library Save system data in file and load system data from file Send system data to servo drive and save system data in servo drive Load system data from servo drive Important: Edited data in EASYRIDER® is transmitted to the RAM of the servo drive and becomes active only after executing the SEND command. Only the instruction “SAVE in EEPROM”, writes data into a non volatile memory. Data is stored there in the event of power failure.

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115

13

Software

13.2

Introduction The selection of the Operating Mode 5 with the Drives 630 Serie activates the complete functionality of all control loops and the BIAS-program processing. The EASYRIDER Software is the programming tool to create, load and save the BIAS Programs.

The programming language “BIAS“

Bedienersprache für intelligente Antriebs – Steuerungen was developed to allow the programming of complex and yet clear programs. Therefore the BIAS commands were divided according to their function into the 12 following command groups: 0. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Move command Move command + parameters Parameter commands ”Parameter from variables” - commands ”Parameter into variables” – commands Control commands Flag commands In-/ output commands Variable commands Mathematics commands 1 Mathematics commands 2 Floating point commands

BIAS – Command overview

With these commands you will be able to program the required machine process in chains of steps The size of a program is limited to a maximum of 1500 BIAS commands The design of the programs occurs with EASYRIDER software at the PC and can be transmitted into the servo drive via serial communication. If you create the BIAS program with the EASYRIDER shell, jump labels, comments and a unit for the position presettings are provided. A further possibility is programming or transmitting and controlling the BIAS program via a field bus respectively. The necessary command coding is listed in the command instruction. During the calculation of a BIAS-program is is possible to start parallel a PLC SPS-Task and/or a Mathematics-Task. The PLC-Task is calculated parallel to the BIAS-Task and has a subset of the commands. Save Table The command is allowed in the PLC-Task only

The Mathematik-Task is calculated in the interruptfree processing time of the drive and has also subset of the commands. Profile value = [Variable X] THe command is allowed in the Math only.

116

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13 ●

Software Program layout A BIAS program consists of 3 basic memory areas. 1. The program definition: contains all definitions for starting and processing a BIAS program, the entries for defining a unit for position presetting and the necessary configurations of the inputs and outputs. 2. The command memory: contains up to 1500 BIAS commands. 3. The synchronous parameters: contain the definitions for the 16 synchronous profile blocks and the 2048 supporting points.

The basic memory areas are part of the BIAS program. In the EASYRIDER for Windows Software the extension is *.WBD.



Execute a BIAS program The BIAS processing is started in operating mode 5 ”position control with BIAS processing” after activating the output stage of the regulator. The first BIAS block to be executed is determined in the BIAS program definition (Parameter ”program start”). After that, the regulator processes one BIAS command sequentially every trajectory cycle. If the BIAS processing encounters a move command, it can be started with the Low-High slope of the start input. Serie Input Configuration 635/ 637/637+/637f/638: X10.11 ”Start input BIAS” (Function 0) 631: X10.9 “Start input ” (Function 3) Alternatively, move commands are started when the start identifier is set before the move command, via the BIAS command ”Start axis”. The following blocks will be processed after a successful start. If the command, ”Wait for “position reached”” follows a move command, block processing will only be continued after the target position is reached. Drive type: 631/635/637 637+/637f/638

Trajectory cycle: 1,899ms 0,844ms

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13 ●

Software Execute a PLC program A cyclic PLC program for supervisory monitoring tasks can be started parallel to the sequential processing of a BIAS program The PLC program is started by processing the BIAS command, ”PLC program”. After the PLC program is activated the programmed PLC commands are processed as of the specified block number. The command ”end of program, mode = 0” within a PLC program causes a jump back to the start of the PLC program. The regulator processes one PLC command sequentially every trajectory cycle. The reaction of the PLC program to the deactivation of the output stage can be adjusted in the BIAS program definition (parameter ”program reaction PLC program”). Thus it is possible to allow the PLC program to continue to process also during the deactivation of the regulator. Is in this mode the first command of the BIAS execution the command “PLC program” the PLC task starts automatically independently of the state (deactive/active) of the drive. In the plc-loop not all of the BIAS commands are allowed. In the 3 command overview the allowed commands are listed. The check of allowed commands is done by the drive during run time! Drive type 631/635/637 637+/637f/638



Trajectory cycle 1,899ms 0,844ms

Execute a Mathematics program A 3 task as math program for supervisory calculation can be started parallel to the sequential processing of a BIAS program and/or PLC program. The mathematics-program is started by processing the BIAS command, ”Mathematics program”. After the mathematics program is activated the programmed mathematics commands are processed as of the specified block number. The command ”end of program, mode =0” within a mathematic - program causes a jump back to the start of the mathematics program. The command ”end of program, mode =3” cancels the mathematics program. The reaction of the mathematics program to the deactivation of the output stage can be adjusted in the BIAS program definition (parameter ”program reaction mathematics program”). Thus it is possible to allow the mathematics program to continue to process also during the deactivation of the regulator. In this mode the command „Mathematic program“ is executed at the first or second line (if the PLC program is on line 1) of the BIAS progam or at line 0 , if the drive is not enabled. The calculation of the mathematics commands is done in the interruptfree calculation time of the drive. In a standard application approx. 10 commands are processed every 2ms

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13

Software

13.3

BIAS - Commands Position = const.

This command is only permitted in the BIAS- task

0

[Variable X] = position This command is only permitted in the BIAS, PLC and MATHTask

1

2

BIAS-execution pointer This command is only permitted in the PLC and MATH-Task

3

[Variable X] =flag Y This command is only permitted in the BIAS and PLC -Task

4

5

Profile value = [variable X] This command is only permitted in the MATH-Task

6

Save table This command is only permitted in the MATH-Task

7

8

PLC-program This command is only permitted in the BIAS and MATH-Task

9

A

B

0

Move position

Move position + parameter

Position = const.

Position = [variable X]

[Variable X] = position

NOP

Flag X = const.

If input X ? const.

[Variable X] = const.

Mathematic program

Table [[variable X]] = const.

[D_Variable X] = [D_Variable Y]+ [D_Variable Z]

1

Move incremental position

Move incremental position + parameter

Speed = const.

Speed = [variable X]

[Variable X] = speed

End of program

If flag X ? const.

If output X ? const.

If [variable X] ? const.

Profile initialization = const.

Table [[variable X]] = [Y_Variable Z]

[D_Variable X] = [D_Variable Y] [D_Variable Z]

2

Move datum

Move datum + parameter

Acceleration = const.

Acceleration = [Variable X]

[Variable X] = acceleration

Sub- program

Flag X = flag Y

Output X = const.

Profile cycle length = [variable X]

[X_Variable Y]= Table [[variable Z]]

3

Move infinite positive

Deceleration = const.

Deceleration = [variable X]

[Variable X] = deceleration

End of Sub-program

Flag X = input Y

Output X = flag Y

[Variable X] = profile value

[ W_Variable X] = [ Y_Variable Z]

4

Move infinite negative

Gear factor = const.

Gear factor = [Variable X]

[Variable X] = gear factor

PLC-program

Flag X = output Y

_____________

[Variable X] = [variable Y] * const.

Profile value = [variable X]

[ X_ Variable Y] = const.

If [D_Variable X] ? [D_Variable Y]

5

Move synchron

Move synchron + parameter

"Position reached" window = const.

“Position reached“ window =[variable X]

[Variable X] = block number

Jump const.

Flag X = flag Y & flag Z

_____________

[Variable X] = [variable Y] / const.

_____________

[Variable [X]] = const.

[D_Variable X] = SIN {[D_Variable Y]}

6

Move CAM profile

Move analogue value + integrator

Remaining position = const.

Remaining position = [variable X]

[Variable X] = actual position Y

Jump [variable X]

Flag X = flag Y | flag Z

_____________

[Variable X] = flag Y

_____________

[Variable [X]] = [variable Y]

[D_Variable X] = COS {[D_Variable Y]}

7

Synchronous settings 1

Move speed + integrator

Ramp filter = const., [variable X]

Maximal current = [variable X]

[Variable X] = analogue input Y

BIAS-Execution pointer = const.

Flag X = flag Y ^ flag Z

_____________

[Variable X] = [variable Y].bit Z number

Save table

[Variable [X]] = [variable Y]

[D_Variable X] = SQRT {[D_Variable Y]}

8

Synchronous settings 2

Move speed + variable

Actual position X = const.

Actual position X = [variable Y]

[Variable X] = latch position Y

Wait for ”position reached”

Flag X = ! flag Y

IBT- mask number = const.

[Variable X] = [variable Y]

_____________

9

Move PID; speed

_____________

If actual position X ? const.

Analogue output X = [variable Y]

[Variable X] = actual speed Y

Wait time = const.

Flag X = status Y

IBT- notification number = const.

If [variable X] ? [variable Y]

_____________

A

Move PID; torque

Cycle length = const.

If actual position X ? [variable Y]

PID scaling

[Variable X] = latch status Y

Wait time = [variable X]

If status X ? const.

CAN Command = [variable X]

B

Set point [axis no.] = const.

Cycle length = [variable X]

Sensor window = const.

Sensor window = [variable X]

[Variable X] = position Y; axis no.

BIAS-execution pointer = [variable X]

Mode X = const.

IBT- data transfer

C

Set point [axis no.] = [variable X ]

Load parameter set X = [variable[Y]]

Sensor position = const.

Sensor position = [variable X]

[Variable X] = value Y

Jump [var.[X]]; length = const.; from

Flag X = [variable Y]

CAN2 Command = [variable X]

D

Move relative

_____________

Execute X commands

[Variable X]. bit[Y] = const.

_____________

Start axis

_____________

Sensor adjustment 1 = [variable X] Sensor adjustment 2 = [variable X]

[Variable X] = axis status, axis no. Y

E

Sensor adjustment 1 = const. Sensor adjustment 2 = const.

_____________

_____________

If [var. X]. bit Y == const. then jump

_____________

F

Stop axis

Stop axis + parameter

Update parameter

PID parameter

_____________

Virtual program

Axis state, axis no. X, bit Y = const., [flag Z]

_____________

Move infinite positive + parameter Move infinite negative + parameter

Command group “Move commands“ Command group “Parameter commands“ Command group “Variable commands“ Command group “Flag commands“ Command group “Conditional jump commands“

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Command group “Program control commands“ Command group “Mathematic commands“ Command group “Output commands“ Command group “CAN- Commands“ Command group “637f commands“

119

[Variable X] = [variable Y] + const. [Variable X] = [variable Y] – const.

[Variable X]= [variable Y] + [variable Z] [Variable X]= [variable Y] [variable Z] [Variable X]= [variable Y] * [variable Z] [Variable X]= [variable Y] / [variable Z]

[Variable X] = [variable Y] ? [variable Z] [Variable X] = [variable Y] ? const.

[D_Variable X] = [D_Variable Y] * [D_Variable Z] [D_Variable X] = [D_Variable Y] / [D_Variable Z]

_____________

_____________

_____________

_____________

_____________

______________

____________

_____________

_____________

_____________

_____________

_____________

_____________

_____________

[Teachvariable X] = [variable Y]

_____________

_____________

_____________

[Variable X] = [teachvariable Y]

_____________

_____________

_____________

14

Appendix

14

Appendix

14.1

STO - Safety - Parameter - Report - Proposal

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15 15

Memo Memo

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16

Modification Record

16

Modification Record

Version

Modification

Chapter

Date

Name

V0106 V0206 V0306 V0406 V0507 V0608

preliminary version preliminary version final version STO - expansion Intenal Version complete 638B

-

07.04.2006 21.08.2006 28.09.2006

N. Dreilich N. Dreilich N. Dreilich N. Dreilich N. Dreilich

122

-

17.07.2008

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Comment

New Photos Phase

We reserve the right to make technical changes. The data correspond to the current status at the time of printing.

Parker Hannifin GmbH & Co. KG Electromechanical & Drives Automation Group Im Sand 14 D-76669 Bad Schönborn Tel. +49(0) 7253 / 9404-0 Fax +49(0) 7253 / 9404-99 [email protected]

www.parker-automation.com

Parker Hannifin GmbH & Co. KG Electromechanical & Drives Automation Group Robert-Bosch-Straße 22 D-77656 Offenburg Tel. +49(0) 781 / 509-0 Fax +49(0) 781 / 509-98176 [email protected]

Parker Hannifin GmbH & Co. KG Electromechanical & Drives Automation Group Von-Humboldt-Straße 10 D-64646 Heppenheim Tel. +49(0) 6252 / 7982-0 Fax +49(0) 6252 / 7982-05 [email protected]

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